Methods and apparatus for forming concrete structures

ABSTRACT

An apparatus for forming concrete structures includes a first truss module and a second truss module, as well as a first and a second concrete form. The apparatus further includes a first and a second actuator device. Each first and second actuator device is mounted on the respective first and second truss module, and each first and second actuator device can move the respective first and second form translationally with respect to the respective first and second truss module. A yoke connects the first truss module to the second truss module to thereby place the concrete forms in generally parallel, spaced-apart relationship. A climbing device attached to the yoke can engage a climb rod and can move the apparatus upward along the climb rod.

CROSS REFERENCE TO RELATED APPLICATIONS

[0001] The present invention claims priority under 35 U.S.C. §120 toU.S. Provisional Patent Application Serial No. 60/313,538, filed Aug.20, 2001 and hereby incorporated herein by reference in its entirety.

FIELD OF THE INVENTION

[0002] The invention claimed and disclosed herein pertains to apparatusand methods for forming concrete structures, and in particular tomethods and apparatus for forming vertical or near-vertical concretestructures.

BACKGROUND OF THE INVENTION

[0003] This invention pertains to methods and apparatus for constructingvertically, oriented, or near-vertical, concrete structures.“Near-vertical” means that the structure, or segments of wholestructures, can be purposely constructed at a slope (or “out-of-plumb”,which is not to be confused with construction plumbness tolerances),tapered (so that an inside or outside surface is not plumb), curved invertical section (for example, as in a cooling tower structure), or acombination of these geometries. Example of such vertical ornear-vertical structures include, without limitation, closed-form shellstructures such as silos, stacking tubes, towers, cooling towers,chimneys, hollow columns, tanks, tank stems, bins, ponds, shear wallchambers, and retaining wall enclosures. Such structures can also beopen-form structures, such as retaining walls, sound walls, shear walls,bearing walls, bunkers, curtain walls, columns, and column bents. Suchstructures further include a combination of closed-form and open-formstructures, known as combination-form structures. Closed-form structuresare those structures where the walls of the structure in a plan view canbe traced an infinite distance (i.e., without reaching any dead ends).That is, there are no “gaps” in the walls of the structure. Closed-formstructures can be made up of a plurality of chambers, a chamber beingdefined as a portion of the closed-form which by itself passes theclosed-form trace test. Open-form structures are those structures wherethe walls of the structure in a plan view cannot be traced an infinitedistance without reaching a dead-end or open-ended wall, no matter whichway the trace progresses or where the trace is initiated. Acombination-form structure has one or more chambers and one or moreopen-ended walls associated therewith (i.e., it is comprised of both aclosed-form structure component and an open-form structure component).The present invention is useful for constructing relatively shortconcrete structures. By “relatively short” I mean the final height ofthe structure is not significantly proportionally larger than the width,length, breadth or diameter of the structure. Examples of relativelyshort closed-form and open-form reinforced concrete structures includethickener tanks, mixing tanks, ponds, shallow bins, bunkers, retainingwall enclosures, retaining walls, tunnel walls, columns, column bents,bearing walls, sound walls, and curtain walls. The present invention isalso particularly useful for constructing relatively tall concretestructures. B y “relatively tall” I mean the final height of thestructure is significantly proportionally larger than the width, length,breadth or diameter of the structure. Examples of relatively tallclosed-form structures include silos, stacking tubes, towers, coolingtowers, tower and tank stems, tanks, chimneys, and bins. Examples ofrelatively tall open-form and combination-form structures includecorrugated retaining walls, silo-open storage bunkers, stacking walls,corrugated sound walls, arch dams, and high-rise shear walls.

[0004] Prior art methods of constructing relatively short concretestructures, such as shear walls, typically employ conventional formingtechniques. For relatively short structures, such as straight walls,conventional reinforced plywood forms are frequently used. For formingrelatively short curved walls, prior art construction methods includethose described in U.S. Pat. Nos. 4,915,345 (Lehmann) and 5,125,617(Miller et. al.). Prior art methods for constructing relatively tallclosed-form concrete structures typically employ one of two approaches:(1) the jump-form method of construction, as generally described in U.S.Pat. No. 3,871,612 to Weaver; or (2) the slip form method ofconstruction, such as generally described in U.S. Pat. No. 5,241,797.However, relatively tall open-form and combination-form structures arenot addressed by slip-forming or jump-forming, and are not economicalwith conventional forming methods except as they are done in a“relatively short” format. This means that these types of relativelytall, open-form structures are not currently produced in a systematic ormachine-like fashion, as are relatively tall closed-form structures.

[0005] Prior art methods of constructing vertical concrete structuresalso employ the method of segmental casting. Segmental casting orconstruction is generally defined as forming sections or segments of alarger reinforced concrete structure (e.g. a closed-form structure suchas a silo, or an open-form structure such as a tall retaining wall) invertical or near vertical segments which are cast with discretehorizontal or near-horizontal levels or cold joints (as in jump-forming)or in a continuous fashion (as in slip-forming). A complete structure isconstructed by casting multiple, vertical or near-vertical segmentseither immediately adjacent to each other, or with gaps between themwhich are later filled with filler or closure segments which are cast inthe same or similar manner. A structure cast in vertical segments can beidentified as having vertical or near-vertical construction jointsrunning the full height of the structure.

[0006] The distinction of “relatively tall” and “relatively short”structures is best defined by the construction methods typicallyemployed to construct these structures, and the inherent technical andeconomic reasons for using such methods. Tall structures tend to beclosed-form structures for storing bulk materials, and so that they willbe of sufficient rigidity and strength to contain the stored materialsand, even during construction, they will be of sufficient rigidity andstrength against horizontal loadings such as wind and seismic forces.Tall, closed-form structures also tend to be prismatic, and are oftensymmetrical about the vertical axis. Accordingly, there are economicefficiencies to be gained in taking a less labor intensive, moresystem-like or machine-like approach to forming the closed-shape. As aresult, the prior art method typically employed is jump-forming orslip-forming, which lend themselves more readily to discrete orcontinuous casting of tall structures. Short structures typically do nothave the geometric efficiencies of tall structures and constructionmethods thereof typically employ conventional forming methods ratherthan more specialized methods such as jump-forming or slip-forming. Inconventional forming methods the concrete forms are often close enoughto the ground or floor level to allow for an entirely different means ofexternal stability than is afforded when the forms are a great distancefrom the ground, and therefore allow for a less costly platform, workdeck, or floor access to the work. A shear wall chamber in a building,for example, though it may be relatively tall compared to the buildingitself, is normally constructed between floors, using each floor as awork platform, and therefore it is not considered “relatively tall”.Such a wall would, however, be considered as “relatively tall” if it isfree-standing for at least several floor heights or more duringconstruction. In summary, relatively short structures are those whichare typically produced using conventional forms because they are only afew stories tall and can therefore be economically accessed andmanipulated from the ground or floor level, and relatively tallstructures are those which are more than a few stories tall and requiremore of a machine-type approach to be most economically accessed andmanipulated to accomplish the casting of reinforced concrete.

[0007] In the prior art jump-form method of construction, a cylindricalshell (closed-form) structure is produced using a series of inside andoutside steel forms continuously attached together within either of thetwo concentric rings, but not between the rings. The rings are stackedone upon another and poured with concrete one level (levels typicallyvary 2′ to 6′ high) at a time until such time as they are 2 or morelevels high. Then the bottom-most set of inside and outside forms are“jumped” or stacked on top of the top-most set of forms. This “jump”process is repeated until the structure height is achieved. Such anapproach realizes a structure comprised of vertically-stacked,monolithic closed-form rings (typically 2′ to 6′ in height and 8″ to 2′in thickness) with “cold” construction joints between rings. Importantelements of the prior art jump-form method of construction are asfollows: (1) The forces of the fluid concrete are resolved in the hooprigidity of the circular ring of forms, and therefore the diameter ofthe structure is limited to a finite diameter, the fluid concrete forcesof which are not greater than the tensile capacity of the forms and formfasteners; (2) the forms are moved upward separately of the work deck bymechanically “jumping” them with jib cranes to the next level, and thework deck moves upward with the use of climber winches which thrust offof the inside forms or off of supports which support from the groundand/or intermittently along the height of the inside surface of thestructure; (3) plumbness of the structure is maintained by referenceswith a transit or plumbob and repositioning of the form heights aboutthe vertical axis of the structure in subsequent “jumps”; (4) the workdeck is only on the inside of the concrete cylinder being constructed;(5) in order to raise the inside forms, the work decking must be removedor tilted out of the way frequently, or gaps must be left between thedeck and the wall face; (6) the jump-form system must be thoroughlyassembled and configured into a cylindrical shape from a large number ofsmall, modular pieces; and (7) the forms are released from the concretesurface by prying them off manually, typically one-at-a-time.

[0008] In the slip-form method of construction, a closed-form shellstructure is effected by moving a single level of concentric, typicallyplywood forms (commonly 4′ tall) continuously upward while installingrebar and pouring concrete until the structure height is achieved. Suchan approach realizes a structure that is essentially monolithicthroughout to the extent that the constructor keeps the operationcontinuous and there are no cold joints. Important particulars of theslip-form method of construction are the following: (1) unlike thejump-form method, the inside and outside forms are tied together withyokes (spaced approximately every 2′ to 8′, depending on the structurerequirements for the form, around the entire perimeter of the structuresection) and therefore the forces of the fluid concrete are resolved inthe moment rigidity of the form-yoke combination; (2) the forms holdthemselves and the accompanying work deck to the structure via acombination of pipes (which become buried in the concrete of thestructure) and jacks that tie into the form-yoke system; (3) the formsand work deck(s) move upward together via thrust of the jacks on thepipes; (4) plumbness of the structure is maintained by references with atransit or plumbob and the form-deck system is re-oriented about thevertical axis of the structure by differential movement of the manyjacks that support the forms and deck around the perimeter of thestructures. There is an inherent flexibility of the pipes which, inconjunction with any imbalance of the deck load, often causes the deckand forms to “spin” or “sway”. This must be controlled by some means ofbracing the pipes against the structure and/or rebar in the structure.There is currently no standard practice for controlling sway; (5) themain work deck is primarily on the inside of the shell or walls of theclosed-form structure being constructed, with a swing scaffold hangingfrom the outside forms to allow finishing of the concrete surface; (6)the inside work deck spans across the diameter or span of the structureand is often comprised of the roof beams and roof decking; (7) the workdeck is constructed such that there is little or no gaps between thedeck and the forms; (8) the slip-form is typically not modular orre-usable and must be thoroughly constructed and configured into theclosed-form shape from a large number of raw material pieces such assteel beams, lumber, and plywood; and (9) the forms are released fromthe concrete formed surface automatically and continuously sinceslip-forming is a continuous process.

[0009] In the conventional forming method for relatively “short”closed-form and open-form structures, a structure is produced byattaching the typically rectangular forms together into panels to form apartial or total wall or structure height. These panels are then backedby whalers to stiffen them between tie points, are tied through the wallby snap ties or through-bolts, and are usually braced or “kicked” to theground or to a nearby floor level or structure with strut supports toplumb and stabilize the forms. Curvilinear structures are produced witheither increments of straight forms or with special curvable forms.These specialized forms are a modified version of the straight form,with allowance for the form stiffeners and/or whaler system to be setmanually to a certain radius. In either the straight wall or curved wallconventional form systems the work platform typically has no particularfunction other than as access to the work at the top of the forms.Important particulars of the conventional forming method of constructionare as follows: (1) Unlike the jump-form method or the slip form method,the inside and outside forms are tied together with special ties thatremain in the concrete, or through-bolts which are extracted aftercasting the concrete, and therefore the forces of the fluid concrete areresolved in the tensile rigidity of the tie or through-bolt; (2) theforms and work plafform(s) are moved upward manually and separatelyafter removal of the ties or through-bolts, and typically a level offorms is left at the top of a pour to rest the next set of forms upon;(3) plumbness of the structure is maintained by references with a level,transit or plumbob, and the form-plafform system is re-oriented aboutthe vertical axis of the structure by adjusting the kicker struts; (4)the work deck is attached to the forms and therefore spans along theperimeter (as compared to jump-forms and slip-forms which span acrossthe formed opening); (5) the work platform being attached to the formshas a small gap between them and the form; (6) the conventional formsystem must be thoroughly assembled and configured from a large numberof small, modular pieces to form a structure; and (7) the forms a retypically released manually from the formed surface by prying action.

[0010] There are several shortcomings with the prior art. Specifically:(1) Vertical segmental construction is not addressed by jump-form orslip-form methods of construction; (2) although segmental constructionis addressed by conventional means, only relatively short structures canbe economically effected by conventional means (i.e., conventionalforming methods of construction are not economically adaptable forconstruction of tall, closed-form or open-form structures); (3) althoughaccurate geometric measurement is possible with all methods ofconstruction given modern surveying equipment, accurate geometriccontrol is not inherently achievable for relatively tall and/or largefootprint structures constructed with the current jump-form or slip-formmethods of construction; (4) modern jump-forming and slip-formingtechniques are very labor intensive; (5) none of the three concreteforming methods described above (jump-forming, slip-forming, andconventional forming) are readily adaptable to both discrete andcontinuous forming; (6) the methods by which jump-forms, slip-forms, andconventional forms are borne by the evolving structure is cumbersome toproductivity; (7) in all three forming methods there are significantlimitations on geometries due to the method of resolution of thehydrostatic force of the concrete between the inside and outside forms;and (8) jump-forming inherently does not allow for a work deck on theouter ring of forms.

[0011] The reason why conventional forms are not readily adaptable forconstruction of tall, open-form structures is inherent in the method:the process of loosening the forms from the wall-ties or through-bolts,lifting the forms vertically to the next level, and attaching thewall-ties or installing the through-bolts is a very cumbersome, laborintensive operation. It also requires the continuous use of very largecranes for great heights.

[0012] None of the prior art methods of constructing concrete structuresaddress both discrete and continuous modes of operation in the verticalor near vertical direction. Jump-forms are not designed, nor are theyreadily adaptable for, slip (continuous) forming. Slip-forms are notdesigned, nor are they readily adaptable for, discrete forming. Althoughdiscrete forming with slip-forms may be an inadvertent result ofstopping the slip form operation and letting the concrete set-up, it isnot an intended function, nor is it a simple matter to get a slip-formmoving again when the concrete sticks solidly to the forms. Conventionalform systems are either designed to be used for horizontal slip-forming(e.g. a tunnel slip-form) or are designed for static (discrete) casting.They cannot be readily transitioned for use in a bi-model fashion.

[0013] Slip forms, though relatively failsafe in the sense that thesupport pipes are continuously buried in the wall, are inherentlycumbersome for placing rebar and concrete because the pipe and yokesystem repeats itself so frequently around the perimeter. Because ofthis, structures with dense rebar and/or large perimeters areimpractical with slip-forming. The through-bolt or tie system whichholds conventional forms to the concrete structure also support the workplatforms. This “tie-through” method of resolving the hydrostatic forcesfrom the concrete and attaching the forms to the concrete is cumbersometo upward progression because of the labor-intensive process of removingand re-inserting bolts or ties. In the prior art chord-form method ofconstruction a vertical portion or vertical segment of a cylindricalstructure is formed by tensioning the concentric set of jump-forms (ofthe type described in U.S. Pat. No. 3,871,612, being approximately 4′tall by 6′ long) to buttress trusses which are positioned vertically ateither end of the vertical segment in modular lengths that are amultiple of the form height. A chord deck and an outside wrap-a-rounddeck span between these buttress trusses, allowing access to both sidesof the segment of jump forms. As with jump-forming, jib cranes are usedto raise or “jump” the forms and climber winches are used to raise thechord deck that interfaces with the perimeter of the evolving wallsegment. As a supplementary hoisting method to the climber winches, theinside and outside chord trusses and attached work-deck are hoisted byway of hydraulic cylinders along guides on the buttress trusses. Closuresegments are effected by reconfiguring parts of the buttress trusses andbolting them to the adjacent segments.

[0014] There are a number of shortcomings with the prior-art chord-formmethod: (1) As with the classical jump-form method which relies on thehoop tensile capacity of the forms to resolve the hydrostatic forcesfrom the concrete, there is a practical limitation on both the geometryand maximum diameter which can be achieved. The geometry is limited tocurved walls, and the radius of the curved wall is limited to thatfinite value where the fluid concrete forces are not greater than thetensile capacity of the forms and form fasteners. A 60′ radius curve isthe practical limit for using these types of forms; (2) As withjump-forming, the chord-form method requires two or more levels offorms, and it requires that these forms be “jumped”, a very laborintensive process; (3) The chord-form method requires heavy buttresstrusses at both ends for the full height of the segment beingconstructed. The capital and mobilization costs associated with thesetrusses are very high and set-up times are long, especially for verytall segments; (4) Vertical alignment of the segment can only beachieved when each new buttress truss is installed, and only to thedegree to which the truss can be tilted out of plumb to correct thealignment.

[0015] What is needed then is a method of, and apparatus for,constructing vertical or near-vertical concrete structures whichachieves the benefits to be derived from similar prior art methods anddevices, but which avoids the shortcomings and detriments individuallyassociated therewith.

SUMMARY OF THE INVENTION

[0016] One embodiment of the present invention provides for an apparatusfor forming concrete structures. The apparatus includes a first trussmodule and a second truss module, as well as a first concrete form and asecond concrete form. The apparatus further includes a first actuatordevice and a second actuator device. The first actuator device ismounted on the first truss module, and the second actuator device ismounted on the second truss module. The first actuator device can movethe first form translationally with respect to the first truss module,and the second actuator device can move the second form translationallywith respect to the second truss module. A yoke connects the first trussmodule to the second truss module to place the first and second concreteforms in generally parallel, spaced-apart relationship. A climbingdevice attached to the yoke can engage a climb rod and move theapparatus in a generally upward direction along the climb rod.

[0017] Another embodiment of the present invention provides for aconcrete forming module which has a semi-flexible concrete form, anactuator frame, a form-shaping actuator supported by the actuator frame,and an elongated form-anchoring member. The form-anchoring member has afirst end connected to the form at an anchor point. The form-anchoringmember is further connected to the actuator frame. The module includes aform-shaping member having a first end connected to the form, and asecond end connected to the form-shaping actuator. The form-shapingactuator is configured to produce relative movement between the secondend of the form-shaping member and the anchor point, to thereby urge atleast a portion of the form into a curvilinear shape.

[0018] These and other aspects and embodiments of the present inventionwill now be described in detail with reference to the accompanyingdrawings, wherein:

DESCRIPTION OF THE DRAWINGS

[0019]FIG. 1 is a plan view depicting a multi-chamber, closed-formconcrete structure that can be constructed using methods and apparatusof the present invention.

[0020]FIG. 2 is a side sectional view of the concrete structure depictedin FIG. 1.

[0021]FIG. 3 is a plan view depicting an open-form concrete structurethat can be constructed using methods and apparatus of the presentinvention.

[0022]FIG. 4 is a side sectional view of the concrete structure depictedin FIG. 3.

[0023]FIG. 5 is a plan view depicting another type of open-form concretestructure that can be constructed using methods and apparatus of thepresent invention.

[0024]FIG. 6 is a side elevation view depicting an apparatus inaccordance with an embodiment of the present invention.

[0025]FIG. 7 is a plan view depicting truss modules used in theapparatus depicted in FIG. 6.

[0026]FIG. 8 is a side elevation sectional view depicting truss modulesused in the apparatus depicted in FIG. 6.

[0027]FIG. 9 is a rear view depicting a form module and a strut moduleused in the apparatus depicted in FIG. 6.

[0028]FIG. 10 is a plan view of the form module and strut moduledepicted in FIG. 9.

[0029]FIG. 11 is a plan view depicting frame components of a trussmodule depicted in FIG. 7.

[0030]FIG. 12 is a rear view depicting end frames and an actuator frameused in a truss module depicted in FIG. 7.

[0031]FIG. 13 is a side elevation view depicting an attitude controlmodule that can be used in the apparatus depicted in FIG. 6.

[0032]FIG. 14 is a side elevation view of a climb module that can beused in the apparatus depicted in FIG. 6.

[0033]FIG. 15 is a side elevation view depicting how the apparatusdepicted in FIG. 6 can be used to produce a vertical wall having onesloped side.

[0034]FIG. 16 is a side elevation view depicting how the apparatusdepicted in FIG. 6 can be used to produce a curving vertical wall.

[0035]FIG. 17 is a plan view depicting how the truss modules depicted inFIG. 7 can be formed into a radial concrete forming shape.

[0036]FIG. 17A depicts the truss modules depicted in FIG. 17, but with awork deck applied over the top of the truss modules.

[0037]FIG. 17B depicts a plan view detail for a form-extending module.

[0038]FIG. 18 is a plan view depicting how the truss modules depicted inFIG. 7 can be formed into a compound curve concrete forming shape.

[0039]FIG. 19 is a plan elevation view of truss modules of a concreteforming apparatus of the present invention that can be used to formcorners in vertical concrete structures.

[0040]FIG. 20 is a plan view of an assembly of apparatus of the presentinvention assembled to form a vertical, rectangular concrete structure.

[0041]FIG. 21 is a plan view depicting how the apparatus depicted inFIG. 6 can be adapted to form a concrete segment using an adjacent,similar apparatus.

[0042]FIG. 22 is a plan view depicting how the apparatus of FIG. 6 canbe adapted to form the end of an open-form vertical concrete structure.

[0043]FIG. 23 is a plan view depicting how several of the apparatusdepicted in FIG. 6 can be joined together to form a system for producinga transition tapered vertical concrete structure.

[0044]FIG. 24 depicts a method of segmentally forming a generallyvertical concrete structure in accordance with the present invention.

[0045]FIG. 25 depicts a side elevation view of yet another embodiment ofan apparatus in accordance with the present invention.

[0046]FIG. 26 depicts a side elevation view of a further embodiment ofan apparatus in accordance with the present invention.

[0047]FIG. 27 depicts a plan elevation sectional view of the apparatusdepicted in FIG. 26.

[0048]FIG. 28 depicts a side view of a concrete form having dynamic formextenders, in accordance with an embodiment of the present invention.

DETAILED DESCRIPTION OF THE INVENTION

[0049] The invention provides for methods and apparatus useful forconstruction of vertical and near-vertical concrete structures. Theapparatus allows for such structures to be formed in either a slip-formtype casting mode, a jump-form type casting mode, or a combination ofthese modes. The apparatus can be used to produce vertical andnear-vertical concrete structures in a segmental-type casting mode, aswell as in a monolithic casting mode. The apparatus of the presentinvention may from time-to-time be referred to herein as a “jump-slipmachine” since it can be used to perform both of these prior art methodsof forming concrete structures. The term “jump-slip machine” isappropriate since the apparatus can cast vertical or near verticalreinforced concrete segments, or whole structures, in either a discrete(jump) or continuous (slip) mode. The methods and apparatus of thepresent invention are particularly useful for forming any size ofclosed-form, open-form, or combination-form reinforced concrete shellstructure, such as hollow columns, cooling towers, reactors, dams,chimneys, tanks, bins, ponds, bunkers, retaining walls, sound walls andcurtain walls, all in vertical or near-vertical oriented segments, ormonolithically.

[0050] As will be described more fully below, one embodiment of thepresent invention provides for a concrete forming apparatus havingradially-matched pairs of automatically or semi-automaticallyretractable (self releasing) form modules that can be actuatedautomatically and/or manually into rectilinear, curvilinear, orgeometric combination sub-segments with the use of translationalactuators and/or adjustable length struts which bear upon and referenceto supporting truss modules. The apparatus can further include awork-deck (“deck”) portion which can move translationally with theforms, and preferably conform to the plan-view shape of the forms by wayof an overlapping fan type work-deck plates and telescoping handrails.Very large, very complex vertical concrete structures can be formedusing apparatus of the present invention when they are joined togetherin series, and when specialized versions of the apparatus (such ascorner-forming adaptations) are used.

[0051] As stated previously, the apparatus of the present invention cancast monolithically, as well as in vertical segments. Further, theapparatus can accomplish continuous casting (slip-forming) as well asdiscrete casting (jump-forming). Virtually any structure geometry can beformed using the apparatus of the present invention, including but notlimited to structures that are straight or curved, prismatic or tapered,and stepped or non-stepped. In addition, the apparatus of the presentinvention uses significantly fewer components than prior art apparatus,requires less manpower to operate, and provides improved geometriccontrol over prior art methods of forming vertical concrete structures.

[0052] Methods and apparatus of the present invention are particularlysuited to construction of medium to tall open-form structures since: (a)the forms are not tied together through the concrete, thereby makingraising of the work deck and forms a relatively simple activity; (b) thebracing of the forms, which ensures that the concrete is cast accuratelyin 3D, is handled readily by the inherent in-plane and out-of-planerigidity of the support truss and yokes and attitude control modules(described below); and (c) removal of the forms and work deck from thestructure is easier than prior art methods.

[0053] Turning now to FIG. 1, a plan view of a multi-chamber,closed-form concrete structure 10 is depicted. This is one example ofthe type of concrete structure that can be produced using methods andapparatus of the present invention. The structure 10 is a bank ofopen-top parallelepipeds which typifies storage bins. The structurecomprises a foundation 11 upon which are supported outer side walls 12,end walls 13, and inner divider walls 14. FIG. 2 depicts a sideelevation sectional view of the structure 10 shown in FIG. 1. FIG. 3depicts in plan view another type of vertical concrete structure thatcan be formed using methods and apparatus of the present invention. Thestructure 20 depicted in FIG. 3 comprises a radially curved wall section22 which is supported on a foundation 21. As depicted, structure 20 isan open-form structure. However, additional similar structures 20 can bejoined together at the wall ends 23 to produce a closed-form structure,such as a circular tank or tower. The wall structure 20 is depicted in aside elevation view in FIG. 4. FIG. 5 depicts a plan view of yet anotherwall-form structure that can be formed using the methods and apparatusof the present invention. Wall structure 30 of FIG. 5 comprises a wallsegment 32 supported by a foundation 31. As can be seen, wall segment 32is in a compound curve form. Such a wall form as wall 32 can be used,for example, as a sound wall adjacent a freeway. In addition to thecurved wall structures depicted in FIGS. 3 and 5, straight wall segmentscan also be formed using the methods and apparatus of the presentinvention. Further, using the methods and apparatus of the presentinvention, any or all of these wall forms can be formed in duplicate,and/or in conjunction with one another, to produce complex open-form orclosed-form structures.

[0054] Turning now to FIG. 6, one embodiment of an apparatus inaccordance with the present invention is depicted in a side elevationview. The concrete forming structure 100 is depicted in the process offorming a vertical concrete structure or wall “W”, which is supported onfoundation “F”. A climb rod or climb pipe 99 is embedded in the wall “W”and the foundation “F”, and is used by the apparatus 100 to pull itselfupward in direction “Y”, as will be described more fully below. Theapparatus 100 includes first forming assembly (also known as a “concreteforming module) 102 and second forming assembly (“concrete formingmodule”) 104. First forming assembly 102 supports a first concrete form114, and second forming assembly 104 supports a second concrete form116. Concrete forms 114 and 116 are in spaced-apart, generally parallelorientation to one another, thus defining void area 90 into which liquidconcrete can be poured to generate the wall “W”. Preferably, forms 114and 116 are fabricated in a semi-flexible manner to allow them to beurged into curvilinear shapes, as will be described more fully below.Forms 114 and 116 are preferably moveably supported by respective trussmodules 118 and 120. Truss modules 118 and 120 are in turn attached tothe respective yoke arms 103 and 105 of the yoke module 106. (Yoke arms103 and 105 generally form a yoke, which is unnumbered in the figure.)Yoke module 106 includes the climbing :40 module 108 (“climbingdevice”), which can engage the climb rod 99, allowing the wholeapparatus 100 to be pulled upward in direction “Y”. A work deck (or“deck”) comprises first deck portion 110 and second deck portion 112,which are attached to respective forms 114 and 116, and supported byrespective truss modules 118 and 120 in a moveable fashion to allow thedeck portions 110 and 112 to be able to move translationally (i.e.,towards or away from the wall “W”) with respect to the truss modules 118and 120.

[0055] As a general description of the operation of the apparatus 100 ofFIG. 6, the truss modules 118 and 120 allow the respective forms 114 and116 to be placed into proper position for the forming of concrete toform the wall “W”. Actuator mechanisms 122 and 126 (associated with form114) and actuator mechanisms 124 and 128 (associated with form 116)allow the individual forms 114, 116 to be moved in directions X and X′,relative to the wall “W” and the truss modules 118 and 120. In this waythe forms can be retracted from the wall and the apparatus 100 can thenbe moved upward (In direction “Y”), as in a jump-forming operation.Likewise, the forms 114 and 116 can be maintained in the concreteforming position while the apparatus 100 is moved upward, as in aslip-forming operation. The manner in which the apparatus 100 isoperated (slip-form or jump-form) will depend on a number of variables,such as the type of structure being formed and the desired surfacefinish of the final structure. Further, forms 114 and 116 are preferablymade from a semi-flexible material, such as heavy gauge sheet steel, toallow t hem to be deformed from a flat shape into a curved shape, aswill be shown and described further below. The form 114 and 116 arepreferably made from steel, the thickness of which will depend on theanticipated hydrostatic force of wet concrete contained between thewalls, as well as the shape of the structure to be formed. Forstructures with a relatively small radius of curvature in the plan view,thinner steel will be used for the forms 114,116 to allow the forms tobe urged into the proper shape. The forms 114, 116 can be furtherstrengthened against hydrostatic forces by the use ofvertically-oriented form stiffening members placed on the outside of theforms (i.e., the side opposite the side which contacts the concrete inthe void area 90).

[0056] The form assemblies 102 and 104 can further include therespective first and second attitude control modules 130 and 132, whichare more fully described below. In addition to providing attitudecontrol (i.e., to “steer” the apparatus 100 in direction X or X′), theattitude control modules 130, 132 also perform the function of providinga force-reacting member to generate reaction forces against the wall “W”resulting from the forces exerted on the forms 114, 116 by the actuatormechanisms 122, 124, 126 and 128. Accordingly, the first and secondattitude control modules 130 and 132 may also be properly known asrespective “first and second reaction force members”.

[0057] Turning now to FIG. 7, the truss modules 118 and 120 of theapparatus 100 of FIG. 6 are depicted in plan view. Truss module 118 iscomprised of first and second end frames 138 and 140, and actuator frame134, which is preferably centered between the end frames. End frame 138and actuator frame 134 are spaced apart, and connected, by first spaceframe 146, while end frame 140 and actuator frame 134 are spaced apart,and connected, by second space frame 148. Space frames 146 and 148 willbe described in more detail below. The two space frames in each trussmodule 118, 120 generally form an articulable space frame assembly, sothat the apparatus 100 includes first and second articulable spaceframes. Truss module 118 supports work deck 110 (FIG. 6) by work decksupport system 202, described more fully below. A series of adjustablestruts 155, 156, 206, 208 are connected at a first end to form 114, andat a second end to actuators (described below) which are supported byactuator frame 134. As will be described more fully below, struts 155,156, 206, 208 allow form 114 to be moved translationally in directions Xand X′, and also allow the form 114 to be deformed from the flat shapedepicted in FIG. 7.

[0058] Truss module 120 of FIG. 7 is constructed similarly to trussmodule 118. That is, truss module 120 is comprised of first and secondend frames 142 and 144, and actuator frame 136, which is preferablycentered between the end frames. End frame 142 and actuator frame 136are spaced apart, and connected, by space frame 150, while end frame 144and actuator frame 136 are spaced apart, and connected, by space frame152. Truss module 120 supports work deck 112 (FIG. 6) by work decksupport system 204. A series of adjustable struts 158, 160, 210, 212 areconnected at a first end to form 116, and at a second end to actuatorssupported by actuator frame 136. Struts 158, 160, 210, 212 allow form116 to be moved translationally in directions X and X′, and also allowthe form 116 to be deformed from the flat shape depicted in FIG. 7. Thestruts 155, 156, 206, 208, 158, 160, 210 and 212 can either be passive,in that they merely track movement of the strut actuators 196, 198(described below), or they can be active, in which case they can beadjusted to a desired length by mechanical means (such as by internalscrew threads, or hydraulic pressure) and thereby be used to adjust theshape of the forms 114, 116.

[0059] The system of struts (155, 156, 206, 208, and 158, 160, 210, 212)in each truss module (118, 120) can be known as respective first andsecond strut modules. Preferably each form 114 and 116 is provided withat least two adjustable struts, and preferably four adjustable struts.In the embodiment described below, each form 114 and 116 is providedwith eight adjustable struts arranged in a 4×2 arrangement (i.e., fourstruts oriented in a first horizontal plane, and four more strutsarranged in a second horizontal plane which is parallel to the firsthorizontal plane).

[0060] Turning now to FIG. 8, a side elevation sectional view of thetruss modules 118 and 120 of FIGS. 6 and 7 is depicted. In the viewdepicted in FIG. 8 the section line has been taken adjacent each of theactuator frames 134 and 136. Further, the struts (155, 156, 206, 208,158, 160, 210, and 212) depicted in FIG. 7 have been removed in FIG. 8for clarity. Each truss module 118 and 120 in FIG. 8 is provided withyoke brackets 180 to allow the yoke (106, FIG. 6) to be attached to thetruss modules. Each truss module 118 and 120 is further provided withattitude module brackets 178 to allow the attitude modules 130, 132 ofFIG. 6 to be attached to the truss modules.

[0061] Truss module 118 (FIG. 8) includes upper actuator frame 134, aswell as lower actuator frame 174; truss module 120 includes upperactuator frame 136, as well as lower actuator frame 176. Lower actuatorframes 174 and 176 are held in spaced-apart relationship from respectiveupper actuator frames 134 and 136 by respective rectangular main frames248 and 249. Adjacent each actuator frame 134, 136, 174, 176 are spaceframe brackets 182, which allow the space frames (146, 148, 150, 152,FIG. 7) to be attached to the actuator frames (e.g., space frame 148 ofFIG. 7 is attached to actuator frames 134 and 174, and space frame 152is attached to actuator frames 136 and 176). Each actuator frame 134,174, 136 and 176 supports actuator devices or mechanisms (“actuators”),which will be described more fully below. The use of two actuator framesfor each truss module provides improved control over positioning of theforms 114 and 116, and allows additional geometric control and shapingof the final form of the concrete structure to be produced.

[0062] Forms 114 and 116 are attached to respective actuator brackets170 and 172, which are in turn attached to first and second upperactuator shafts (actuator members) 184 and 186, and first and secondlower actuator shafts 188 and 190, by hinged connectors (e.g., pins,ball joints, or any such pivotal connector) 192, allowing movement ofthe actuator brackets 170, 172 with respect to shafts 184, 186, 188 and190 (FIG. 8). Actuator brackets 170, 172 serve to distribute the forceexerted by the actuator shafts 184, 186, 188 and 190 over the face ofthe forms 114 and 116, and also serve to stiffen the forms against thehydrostatic forces of wet concrete contained between the forms. Decksplates 110 and 112 are attached to respective actuator brackets 170 and172 by respective hinges 162 and 164, allowing rotational movement(clockwise or counterclockwise, as viewed in FIG. 8) of the deck plates110 and 112 with respect to forms 114 and 116. This allows the forms 114and 116 to be “tilted” (as in 116 a), while leaving the decks 10, 112level with the ground. Decks 110 and 112 are also provided withrespective handrails 166 and 168. Deck 110 is supported on truss module118 by deck support system 202, and deck 112 is supported on trussmodule 120 by deck support system 204. The deck support systems 202, 204will be described more fully below. Preferably, lower pivotal connection192 is a connection (such as a slotted connection) which allows slightvertical movement of the form (114 or 116) with respect to the upperpivotal connection (also 192), to allow the form (114, 116) to “tilt”(as in 116 a) without causing a binding of an actuator member (184, 186,188, 190) in the associated actuator frame (134, 136, 174, 176,respectively). This feature will account for the effective “shortening”in the effective height of a form face as it is tilted relative to theother form face.

[0063] Actuator shafts 184, 186, 188 and 190 are preferably smooth atthe area where they enter bushed bores (not numbered) in the actuatorframes 134,136, 174 and 176 proximate the forms 114 and 116. Thereafter,the shafts 184, 186, 188 and 190 are preferably threaded so that theycan be engaged by screw-thread actuators 196, 198 and 200. Althoughhydraulic actuators can be used for actuators 196, 198 and 200, screwthread actuators are preferable since they provide positive engagementof the shafts 184, 186, 188 and 190, even in the event of loss of power.The screw-thread actuators 196, 198, 200 can be actuated by electricmotor, hydraulic force, or manually. Each actuator frame 134, 136, 174and 176 comprises first and second strut actuators (actuator devices)196 and 198 which are preferably moveably mounted in actuator frames134, 136, 174 and 176, and the actuators 196, 198 are preferablyconfigured to move along guides 194 within each actuator frame.Actuators 196 and 198 are preferably screw thread actuators (such asscrew jacks), and engage the threads of shafts 184, 186, 188 and 190.Each strut actuator 196, 198 is preferably connected to two struts. Thiscan be seen by viewing FIG. 8 in conjunction with FIG. 9. FIG. 9 is arear elevation sectional view of truss module 120 of FIG. 8 with thesection being taken immediately behind strut actuators 196, and showsthe struts associated with module 120. Specifically, struts 160 and 158are connected to upper strut actuator 196 in upper actuator frame 136,struts 212 and 210 are connected to upper strut actuator 198 (not seenin FIG. 9) in upper actuator frame 136, struts 214 and 216 are connectedto lower strut actuator 196 in lower actuator frame 176, and struts 218and 220 are connected to lower strut actuator 198 (not seen in FIG. 9)in lower actuator frame 176. The system of struts (158, 160, 210, 212,214, 216, 218 and 220 of FIG. 9) can alternately be termed a “strutmodule” or a form-shaping module, the latter comprising form-shapingmembers (e.g., any or all of the indicated struts). The actuator framesare not specifically shown, and are not numbered, in FIG. 9. ViewingFIG. 7 and FIG. 8 together, struts 155 and 156 are connected to upperstrut actuator 196 in upper actuator frame 134, and struts 206 and 208are connected to upper strut actuator 198 in upper actuator frame 134.Lower strut actuators 196 and 198 in lower actuator frame 174 aresimilarly connected to struts that are equivalent to struts 214, 216,218 and 220 of FIG. 9. Each of the eight strut actuators 196 and 198 canbe individually actuated, or they can be actuated in concert, or in anycombination. When strut actuator 196 or 198 is actuated, and therespective shaft 184, 186, 188 or 190 is held in a fixed position in theactuator frame (134, 136, 174, 176), then the actuator 196 or 198 iscaused to move along guides 194 within the actuator frame in atranslational position relative to the shaft, as indicated bydirectional arrow “A” in strut frame 176 (FIG. 8). As will be more fullydescribed below, use of the strut actuators can cause the shape of theforms 114 and 116 to be altered, thus allowing the apparatus 100 to beused for forming curved concrete segments.

[0064] In addition to the strut actuators 196 and 198, each actuatorframe 134, 136, 174 and 176 is preferably provided with a main actuator(actuator device) 200 (FIG. 8), so that the apparatus 100 includes atleast first and second main actuator devices. Main actuators 200 arealso preferably screw-jack type actuators and engage screw threads onshafts 184, 186, 188 and 190. When an actuator 200 is actuated, theassociated shaft (184, 186, 188 or 190) moves translationally relativeto the associated actuator frame (134, 136, 174 or 176), as indicated byarrow “B” in actuator frame 176. When this occurs, the strut actuators(196 and 198) move together with the shaft within actuator frame,causing the form (114 and/or 116) to move in direction “B”. In this waya form 114 or 116 can be pulled away from the formed concrete structure(e.g., wall “W” of FIG. 6), or moved towards the area where the wall “W”is to be formed (defined by void 90 of FIG. 6). For example, ifactuators 200 (FIG. 8) in actuator frames 134 and 174 are actuated inconcert, form 114 can be moved leftward (as viewed in FIG. 8) to theposition indicated by 114 a. Further, a form (114 and/or 116) can betilted with respect to vertical orientation by actuating only the mainactuator 200 in either the upper or lower actuator frame (or byoperating the upper and lower actuators 200 at differential rates). Forexample, if only upper main actuator 200 in actuator frame 136 isactuated (while lower main actuator 200 in frame 176 is not actuated),then the upper portion of form 116 can be tilted in a clockwisedirection (as viewed in FIG. 8) to the position indicated by 116 a. Fromthe foregoing description, it can be seen that actuators 200 mightproperly be termed “form translating actuators” since they can be usedprimarily to move forms 114 and 116 in translational direction towards,and away from, the face of the structure “W” (FIG. 6) being formed (orto be formed). Likewise, actuators 196, 198 might properly be termed“form shaping actuators” since they are used primarily to reshape forms114 and 116 from a flat (linear) shape to a non-linear or curvilinearshape (e.g., as depicted in FIG. 17). Moreover, the system of formshaping actuators 196, 198 (FIG. 8) and struts (158, 160, 210, 212, 214,216, 218, 220, FIGS. 7 and 9) can be termed “first and second formshaping devices”, since their primary function is to alter the shape ofthe forms 114, 116. Generally, the “form shaping device” comprises aform shaping actuator (196, 198) mounted on the respective truss module(118, 120), and a form shaping member (e.g., struts 210, 212, 214, 216,218, 220) having a first end connected to the respective form (114 or116), and a second end connected to the form shaping actuator (196,198). The form shaping actuator (196, 198) is configured to move thesecond end of the form shaping member (strut) relative to the respectivetruss module (118, 120), thereby urging the form (114, 116) into acurvilinear shape. As mentioned above, actuators 196, 198 and 200 (aswell as actuators 260 and 264, described below with respect to theattitude control module 130 of FIG. 13) are preferably screw jack typeactuators, and can be actuated manually, electrically or hydraulically.Actuators 196, 198, 200, 260 and 264 can also be hydraulic actuators(e.g., hydraulically driven piston actuators or hydraulically drivengear reduction drives), electric actuators (e.g., gear reduction drivesdriven by electric motor), and any other type of actuator which allows amember to be repositioned with respect to a supporting frame.

[0065] Further, main actuators 200 can be individually placed in a“locked” position so that the jack-screw within the actuator 200 is notfree to rotate within the actuator 200, thus fixing the shaft (184, 186,188 and/or 190) relative to the associated actuator frame (134, 136, 174and/or 176). When a main actuator is placed in a “locked” position,actuation of a strut actuator 196, 198 will cause the actuator 196, 198to move within the actuator frame (134, 136, 174, 176) along the guides194, in the manner described above. This will result in altering theshape of the form 116 from the flat shape depicted in FIG. 7 to a curvedshape, as will be describe further below. Turning to FIG. 10, the strutsystem associated with truss module 120 of FIGS. 7 and 8 is depicted ina plan view. Upper strut actuators 196 and 198 can be seen. It is usefulto briefly view FIG. 9, which depicts a sectional view of the strutsystem depicted in FIG. 10, wherein the section is taken between thestrut actuators 196 and 198. FIG. 9 depicts the set of upper struts 212,160, 158 and 210 which are depicted in the plan view of FIG. 10, as wellas the lower set of struts 218, 214, 216 and 220 which cannot be seen inFIG. 9. As can be seen by viewing FIGS. 9 and 10, there are sets ofstruts: two upper inner struts 160, 158, two upper outer struts 212,210, two lower inner struts 214, 216, and two lower outer struts 218,220. Each strut is preferably configured to be a variable length member.Preferably, each strut comprises an inner and an outer cylinder whichare slidable with respect to one another. However, other configurationscan be employed to allow the struts to be of variable length, such as asliding rail configuration.

[0066] Turning back to FIG. 10, first ends of upper outer struts 212 and210 are pivotally connected to strut actuator 198 by pins or ball joints197, and second ends of upper outer struts 212 and 210 are pivotallyconnected to respective form frame members 226 and 228 by pins or balljoints 213. Likewise, first ends of upper inner struts 160 and 158 arepivotally connected to strut actuator 196 by pins or ball joints 195,and second ends of upper inner struts 160 and 158 are pivotallyconnected to respective form frame members 222 and 224 by pins or balljoints 215. A similar connection configuration is provided for lowerstruts 218, 214, 216 and 220, as indicated in FIG. 9. Likewise, a set ofeight complementary struts for truss module 118 (FIG. 7) are pivotallyconnected to strut actuators 196 and 198 of truss module 118, and form114 associated therewith. Viewing FIG. 10, the function of the strutactuators 196 and 198 in changing the shape of the form 116 can beappreciated. As shaft 186 is held in a fixed position relative to trussmodule 120 (FIG. 8), by virtue of the screw-jack within main actuators200 being “locked” (as described above), form 116 can be deformed fromthe flat position indicated to a concave or a convex position (relativeto the outside surface “OS” of form 116). For example, if strut actuator196 is translated along shaft 186 in direction “P” while strut actuator198 is held fixed relative to shaft 186, then the form 116 will beforced into a convex shape, whereas if strut actuator 196 is translatedalong shaft 186 in direction P′ while strut actuator 198 is held fixedrelative to shaft 186, then the form 116 will be forced into a concaveshape. A similar result is achieved if strut actuator 198 is moved along shaft 186 while strut actuator 196 is held in a fixed position. Ascan be appreciated, by variably positioning strut actuators 196 and 198relative to one another, and relative to shaft 186 (and thus theassociate truss module 120 of FIG. 8), a variety of curved shapes forform 116 can be achieved. While truss modules 118 and 120 are depictedas each having eight struts, a lesser or greater number of struts can beused. The number of struts used can depend on the anticipated finalstructure to be formed using the apparatus. For example, the shape ofthe concrete structure to be produced, and the anticipated hydrostaticforces from the liquid concrete, will determine whether a lesser numberof struts can be used (a large number of struts will accommodate morecomplex geometries, and will also resist greater hydrostatic loads).

[0067] Turning now to FIG. 11, a plan view of the truss module 120 ofFIG. 7 is depicted in a plan view, but without the strut system depictedin FIG. 10. That is, FIG. 11 can be considered as the truss module 120depicted in FIG. 6 minus the strut system depicted in FIG. 10. FIG. 11allows the space frames 152 and 150 of FIG. 7 to be seen more clearly.The components of the truss module depicted in FIG. 11 include the endframes 144 and 142, the actuator frame 136, and the space frames 152 and150 which place the respective end frames 144 and 142 in spaced-apartrelationship from the actuator frame 136. End frames 144 and 142 areprovided with connection brackets 199, allowing the apparatus 100 (FIG.6) to be connected to adjacent, similar apparatus and therefore producean integral concrete forming system (as will be described furtherbelow). Each space frame 150, 152 is pivotally connected to respectiveend frame 142, 144 by pins 238 at brackets 199, and each space frame150, 152 is pivotally connected to the actuator frame 136 by pins 239.Further, each space frame 150, 152 is preferably comprised of adjustablelength links 234, 236, allowing the end frames 142 and 144 to move indirections P and P′ relative to the actuator frame 136 (similar tomovement of the strut actuators 196 and 198 relative to the shaft 186,as indicated in FIG. 10). To achieve this movement of end frames 142 and144 relative to actuator frame 136, each space frame 150 and 152 cancomprise adjustable links. Specifically, each space frame 150, 152 caninclude an upper forward adjustable link 236 (proximate the associateform, in this case form 116 of FIG. 7), and an upper distal adjustablelink 234 (distal from form 116). Adjustable links 234 are preferablytwo-part adjustable links, having first part 234 a and second part 234 bwhich are pivotally connected to space frame cross member 247 by pivotpin 241. The use of a two-part adjustable link 234 allows a greaterrange of adjustability of the space frames 150, 152. Each space frame150 and 152 is also provided with a complementary lower forwardadjustable link (not seen in FIG. 11) and a lower two-part distaladjustable link (not seen in FIG. 11), to thereby generate adjustable,generally “box-shaped” (i.e., three dimensional) space frames 150, 152between the respective end frames 142, 144 and the actuator frames 136and 176 (FIG. 8). Preferably, the adjustable links 234, 236 areconfigured to be secured into their adjusted positions by pins, screws,clamps or other means which prevent relative movement between thesliding members of the adjustable links. Each space frame 150, 152 canalso be provided with cross brace 247 and diagonal brace members 246 toprovide additional structural rigidity to the space frames 150, 152 tothereby resist the hydrostatic forces imposed on the space frames byliquid concrete placed between the forms 114 and 116 (FIG. 6), which areimparted to the space frames via the actuators 196, 198 and 200 (FIG.8). It will be appreciated that space frames 146 and 148 of truss module118 (FIG. 7) can be constructed similarly to space frames 150 and 152depicted in FIG. 11. The space frames 146, 148, 150 and 152 (FIG. 7), inconjunction with the actuator frames 134, 136, and the end frames 138,140, 142 and 144, generally provide support for the deck modules 110 and112 (FIG. 6), as described in more detail below.

[0068] Turning briefly to FIG. 17, a plan view of truss modules 118 and120 is depicted, showing how the space frames 146 and 148 of trussmodule 118 articulate about actuator frame 134 to accommodate the convexshape of form 114, while space frames 150 and 152 of truss module 120articulate about actuator frame 136 to accommodate the concave shape ofform 116. However, it will be appreciated that the form ends of forms114 and 116 will not align if the forms 114 and 116 are of the samelength, due to the greater radius of form 116 than form 114. Thissituation can be addressed by the use of a form extender, as depicted inFIG. 17B. FIG. 17B depicts a plan view detail of a portion of the trussmodule 120 of FIG. 17. Pivotally attached to the form support member 228is a form extender 370 which includes extender form face 372. Theextender form face 372 is preferably of the same curvature as the outerform 116. The use of extender forms 370 increase the arc length of theouter form 116 to match-up with the arc length of the inner form 114.

[0069] In addition to providing static form extenders, such as formextender 370 of FIG. 17B, the apparatus 100 can further include dynamicform extenders, as depicted in FIG. 28. FIG. 28 depicts a front view ofform 114 (of FIG. 6, for example). Form 114 is provided with two dynamicform extenders 927 and 928, one form extender being provided for eachside edge of the form 114. Form extender 927 is defined by extender edge930. Form extenders 927 and 928 are moveable in directions “D” and “K”with respect to for edges 932 and 934 to thereby allow the effectivewidth of the form 114 to be changed (either increased or decreased). Inaddition to moving laterally, as indicated by laterally moved formextender edge 930 a, the form extenders 927 and 928 are preferably alsorotatably positionable with respect to the form edges 932 and 934, asindicated by rotated form extender edge 930 b. In this way complexshapes, such as concave cooling towers and domes, can be formed usingthe apparatus of the present invention. The form extenders 927 and 928can be generally flat panels which are slidably mounted to the outerside (non-concrete side) of forms 114 and 116. In another configuration,the form extenders can be in the form of roller sheets which areunrolled as additional form extension is required (or conversely,“reeled-in” as form width contraction is required).

[0070] The truss module structure 120 depicted in FIG. 11 supports thedeck support system 204, and in the same manner the truss modulestructure 118 depicted in FIG. 6 supports the deck support system 202.As seen in FIG. 11, the deck support system 204 (which supports deck 112of FIG. 6) comprises translatably associated deck support members 240and 242 (two each) which are supported on space frames 150 and 152. Decksupport members 240 are fixed to the end frames (142 or 144), and decksupport members 242 are fixed to the actuator frame 136. Deck supportmembers 240 and 242 are supported by space frame cross members 247, andare constrained by brackets 244. A similar configuration is employed fordeck support system 202 (FIG. 7). Turning to FIG. 12, the truss module120 of FIG. 11 is depicted in a rear view, but a number of the spaceframe components have been removed for clarity. FIG. 12 shows how thedeck support members 240, 242 are supported on end frames 142 and 144,cross members 147, and actuator frame 136. Turning again to FIG. 17, itcan be seen that the deck support members 240 and 242 on truss module120 have been translated away from one another due to the expansion ofthe space frames 150 and 152, while the deck support members 240, 242 ofthe deck support system 202 of truss module 118 have been translatedcloser to one another.

[0071] The deck support systems 202 and 204 (FIG. 7) can be used inconjunction with an adjustable-area decking system. Turning to FIG. 17A,a plan view of the truss modules 118 and 120 depicted in FIG. 17 isshown, but the truss modules 118 and 120 are shown in FIG. 17A withadjustable-area deck plate systems 110 and 112 laid on top of the decksupport systems (202 and 204, FIG. 17). Each deck plate system 110 and112 includes a plurality of under-deck plates 294 which are preferablyrigidly attached to the truss modules 118 and 120, and are placed inspaced-apart relationship from one another. The under-deck plates 294can be perforated to allow water and concrete to fall away from the worksurface. Placed over the gaps between the under-deck plates 294 are aseries of over-deck plates 292 which are preferably hingedly connectedto the truss modules 118 and 120. The over-deck plates 292, incombination with the under-deck plates 294, form a fan-type work decksystem 110, 112, which can accommodate the expanded, or contracted, orcurved, or straight shapes of the truss modules 118, 120 by relativemovement of the deck plates 292 and 294 to one another. The deck platescan be fabricated from metal, such as expanded steel grating, or from anon-metallic material such as fiber reinforced plastic (“FRP”), whichprovides less friction between the upper-deck plates and the lower-deckplates. A non-metallic deck plate material also allows a degree offlexibility in the deck plates (within the plane of the deck plates) toaccommodate changes in geometry of the associated truss module on whichthe work deck is supported. In addition to the fan-type deck platesystems 110 and 112, the truss modules can be provided with telescopinghandrail systems 166 and 168 to allow the handrails at the outer edgesof the work decks 110, 112 to also accommodate the change in size of thetruss modules 118, 120 as they are placed in different configurations.As seen in FIG. 8, the work decks 110 and 112 are supported by, but notfixed to, the deck support systems (respectively, 202 and 204) so thatthe work decks (110, 112) are slidably disposed with respect to (i.e.,can move in directions P and P′ relative to) the truss modules(respectively, 118, 120), but in conjunction with the respective forms114 and 116. That is, the work decks 110, 112 are free to translatealong with respective forms 114 and 116 relative to respective trussmodules 118 and 120. Hinged connection 162 (between work deck 110 andform 114) and hinged connection 164 (between work deck 112 and form 116)allow the work decks 110 and 112 to stay in a relatively fixed positionwith respect to the forms (respectively, 114 and 116). In this way, asthe forms 114 and 116 are translated in directions P and P′ (FIG. 8),the work decks 110 and 112 stay in close proximity to the associatedform (114 or 116), thus eliminating a gap between the form and the workdeck, as results in prior art concrete forming apparatus.

[0072] Turning to FIG. 13, a side elevation detail of attitude controlmodule 130 of FIG. 6 is shown. As described above, the attitude controlmodules 130, 132 (FIG. 6) can also be considered as reaction forcemembers to facilitate pulling the forms 114, 116 away from the face ofthe concrete structure “WV” using the actuators 196 and 198. As shown inFIG. 13, attitude control module 130 is connected to truss module 118 atflange 178. Attitude control module 130 comprises main frame 248, whichsupports upper attitude control actuator 260 and lower attitude controlactuator 264. Actuators 260 and 264 engage respective attitudepositioning shafts (“attitude positioners”) 254 and 256, which can bethreaded shafts (similar to shaft 184, FIG. 8). When shafts 254 and 256are threaded, then actuators 260 and 264 can be jack-screw actuators,similar to actuator 200, described above. Actuators 260 and 264 arepreferably set in a fixed position in frame 248. Positioning shafts 254and 256 are depicted as being fitted with wheels 266, which allow theattitude module 130 to track along the finished concrete wall “W”.Wheels 166 can be replaced with pads to reduce the number of movingparts, but wheels 166 can cause less damage to the face of the wall “W”as the apparatus 100 moves upward. Further, a combination of wheels andpads can be used. In this instance the wheels can be spring-loaded sothat they are biased towards the climb-rod 99, and therefore contact theformed wall “W” when the forms 114, 116 translate outward and away fromthe formed concrete wall. However, when the forms 114 and 116 aretranslated towards the formed wall “W”, the spring-loaded wheels will bepressed into the attitude control modules 130, 132, and the pads willcontact the formed wall. In another embodiment, the wheels of theattitude control modules 130, 132 can be replaced with caterpillartractor-type treads, which allows the reaction force of each of theattitude control modules to be spread over a larger surface area of theformed wall “W”. As is apparent, radial attitude control module 132 ofFIG. 6 can be constructed similarly to attitude control module 130 ofFIG. 13 (described above).

[0073] The attitude control modules 130 and 132 can be attached to theactuator frames 174, 176 (FIG. 8), end frames 138, 140, 142, 144, FIG.7), and/or the space frames (146, 148, 150, 152, FIG. 7). The attitudecontrol modules 130 and 132 can also be an integral part of the trussmodules 118, 120 so that they are not “attached to” the truss modules,but are part of the truss modules. In this latter instance, the attitudecontrol module frame 248 is but an extension of the truss module 118,and connection flanges 178 are not present.

[0074] In operation, attitude control actuators 260 and 264 can be usedto individually position the radial attitude positioning shafts 254 and256, and thereby alter the position of the apparatus 100 with respect tothe climb rod 99 (FIG. 6). Further, the attitude control actuators 260and 264 (in radial control modules 130 and 132) can be used inconjunction to cause the attitude positioning shafts 254 and 256 to pushthe forms 114 and 116 towards or away from the evolving wall “W”.Turning to FIG. 15, a side elevation view of the apparatus 100, similarto the depiction in FIG. 6, is shown. However, in FIG. 15 the apparatus100 has been adjusted so that the wall “W(A)” being formed has a firstside S1 which is essentially vertical, and a second side S2 which is afew degrees off of vertical. This produces a tapered wall “W(A)”. Toaccomplish this, form positioning shafts 186 and 190 in truss module 120have been adjusted to place form 116 in a slight tilted position. (It isnoted that deck 112 is tilted with respect to form 116 to retain thework deck 112 in a level position.) Further, radial attitude positioningshafts 250 and 252 in radial positioning module 132 have been adjustedso that they contact the sloping side S2 of wall W(A), but keep theforming assembly 104 (other than form 116) oriented in a verticalposition. Turning now to FIG. 16, yet another variation on the shape ofa wall which can be formed using the apparatus 100 is depicted. In FIG.16 the apparatus 100 is being used to form a wall “W(B)” having discretebends B1, B2, etc. To accomplish the bends B1, B2, etc., the attitudecontrol modules 130 and 132 are periodically readjusted to rotate thetruss modules 118 and 120 (and thus forms 114 and 116) in a clockwisedirection. Again, it is noted that work decks 110 and 112 remain levelwith respect to the foundation “F” so that workers can work on a levelplatform. In addition to the tapered wall “W(A)” of FIG. 15, and thestaggered wall “(B)” of FIG. 16, it will be appreciated that theattitude control modules 130 and 132 can be used to generate a number ofdifferent wall shapes, including a double tapering wall (tapering eitherupward or downward), a straight but sloping wall, a continually curvingwall, and a “stepped” wall (wherein the thickness of one or both sidesof the wall are decreased (or, less commonly, increased) relative to aconstant wall-thickness midpoint in a discrete, incremental manner.

[0075] Turning now to FIG. 14, a side elevation detail of the yokejacking system 108 of FIG. 6 is depicted. The yoke jacking system 108 isconnected to the first and second arms 268 and 270 of the yoke 106 byflanges 262 and 274. As depicted, the yoke jacking system 108 comprisesa yoke actuator frame 258 which supports upper and lower climb actuators272. Climb actuators 272 can be annular screw jacks or hydraulic jackswhich can alternately grip the climb pipe 99 to effect upward movementthe yoke 106 in direction “Y” along the axis of the climb pipe 99. Climbactuators 272 can be operated in discrete fashion to effect a“jump-form” type operation of the concrete forming apparatus 100, orthey can be operated in a continual fashion to effect a continuous“slip-form” casting mode. Turning again to FIG. 8, as was describedpreviously, the yoke 106 of FIG. 6 is attached to the truss modules 118and 120 by yoke flanges 180.

[0076] Preferably, yoke 106 is pivotally attached to lower yoke flanges180, and is adjustably connected to upper yoke flanges 180. This isdepicted in FIG. 13, which shows a ball-joint type pivot hinge 273 whichis placed between the lower yoke attachment bracket 180 and the lowerend of the yoke arm 286. The yoke positioning device further comprisesan actuator 275 which causes relative movement between the yoke 106 andthe truss module 118. The preferred direction of movement is into andout of the plane of the sheet on which the figure is drawn. In this way,in a side view of the truss module 118 of FIG. 13, the yoke 106 can bemoved pivotally in either a clockwise or a counterclockwise rotationaldirection relative to the lower pivot connection 273. Since the yoke isanchored to the climb rod 99 (FIG. 14), the truss module 118 will bemoved (rather than the yoke), allowing sway control of the apparatus 100as the yoke actuators 272 move the apparatus 100 in the upward “Y”direction. As can be appreciated, a similar arrangement as that shown inFIG. 13 can be provided for truss module 120. In this way the climbingdevice 108 can be plumbed or adjusted in directions “R1” or “R2” withthe attitude control modules and, in plan view, in directions orthogonalto “R1” and “R2” (i.e., into and out of the plane of the sheet on whichFIG. 8 is drawn) with the tangential or sway control effected byactuator 275 acting about the lower ball-joint type pivot hinge 273referenced to a predetermined reference point, such as a point on theground, by using yoke adjustment devices. The yoke adjustment devicescan be made additionally adjustable in the “R1” and “R2” directions toaugment the attitude control effected by the attitude control modules130 and 132, for example, with threaded nuts on a threaded shaft,wherein the nuts are placed between each yoke arm (268, 270) and eachflange 180 in conjunction with sway control devices 273 and 275 so thatthe nuts can be used to urge the yoke arms in a direction (“inward” or“outward”) relative to the flange 180. It will be appreciated that afurther means of tangential or sway control (i.e., in a direction intoand out of the plane of the sheet upon which FIG. 8 is drawn) can beaccomplished in a global or system sense by attitude control modules130, 132 of associated forming apparatus 100 oriented with a vectorcomponent in the direction of the sway of climbing device 108 into orout of the plane of the sheet upon which FIG. 8 is drawn. As an example,the attitude control modules stabilizing yokes 106B and 106D inlocalized directions “R1” and “R2” along the short sides of system 400of FIG. 20, especially near the corners, can accomplish the sway controlof yokes 106A and 106C along the long sides of system 400. In a likemanner, the attitude control modules stabilizing the yokes 106A and 106Cin localized directions “R1” and “R2” along the long sides of system400, especially those nearest the corners, can accomplish the swaycontrol of yokes 106B and 106D along the short sides of system 400.

[0077] As previously discussed, FIG. 17 shows how the truss modules 118and 120 can be configured using the adjustable struts (155, 156, 206,208, 158, 160, 210, 212, etc.) and the space-frame adjustable links(234, 236), described above, for placing the apparatus 100 in a radialarc shape. By connecting several so-shaped apparatus 100 together, aclosed-circle concrete forming apparatus can be formed, and theassemblage of the discrete concrete forming apparatus into theclosed-circle concrete forming apparatus can then be used to generate avertical silo. Turning to FIG. 18, another shape into which theapparatus 100 be can be configured is depicted in plan view. In FIG. 18the truss modules 118 and 120 have been adjusted to place the forms 114and 116 into parallel compound curves, so that when the void area 90defined between the forms is filled with concrete, a portion of theconcrete structure 30 of FIG. 5 will be produced. As can be observed inFIG. 18, adjustable links 146 a and 148 a of respective space frames 146and 148 are adjusted to different lengths (as are the forward adjustablelength members 146 b and 148 b). Likewise, the inner struts(“form-shaping members”) 155 and 156 are set to different lengths, asare the outer struts 206 and 298. From this observation it is apparentthat the face of each form (114, 116) can be set to a separate shapeabout the form-shaping member (e.g., 184, FIG. 18) when separatelyadjustable space-frame links (e.g., 146 a, 146 b, 148 a and 148 b) areused in conjunction with separately adjustable form-shaping members(e.g., struts 155,156,206 and 208).

[0078] Turning briefly to FIG. 23, a plan view showing three of theapparatus 100 of FIG. 6 joined together is depicted. The truss modules118 a and 120 a of apparatus 100 a are adjusted to place the respectiveforms 114 a and 116 a in parallel, straight orientation with respect toone another, generating straight pour zone Z1. Truss modules 118 b and120 b of apparatus 100 b are connected at an angle to respective trussmodules 118 a and 120 a. Further, truss modules 118 b and 120 b areadjusted to place respective forms 114 b and 116 b in non-parallelorientation with respect to one another, resulting in the widening taperzone Z2. Finally, truss modules 118 c and 120 c of apparatus 100 c areconnected at an angle to respective truss modules 118 c and 120 c. Trussmodules 118 c and 120 c are adjusted to place respective forms 114 c and116 c in parallel orientation with respect to one another, resulting ina second straight zone Z3. In this way a wall of variable width (in theplan view) can be constructed. As can be seen by viewing FIGS. 15through 18 and 23, and as will be described fuller below, it is apparentthat by adjusting the truss modules on the apparatus 100 to variousshapes, and by connecting several of the apparatus 100 together, andusing the attitude control modules 130 and 132 (FIG. 6), an almostinfinite variety of shapes of concrete structures can be formed by usingone or more of the apparatus 100 of the present invention. For example,a curved, tapered open-form structure such as a dam can be continuouslyformed. Also, a closed-form, circular structure having a domed concreteroof, such as a nuclear power plant, can also be formed. Likewise, asound wall adjacent a freeway can be produced, the sound wall havingperiodic undulations (such as in FIG. 5) to break up sound, and havinglocal undulations to follow the path of the freeway.

[0079] In addition to the standard concrete forming apparatus 100depicted in FIGS. 6 through 12, specialized concrete forming apparatuscan be provided, in accordance with the present invention. FIG. 19depicts one such specialized apparatus 300. The apparatus 300 of FIG. 19is shown in a plan view, and the yoke (106, FIG. 6) and work-decks 110,112 (FIG. 6) have been removed for clarity. The apparatus 300 of FIG. 19is specially constructed to form corners of a concrete structure, andincludes a first truss module 318 which supports forms 314 a and 314 b,and a second truss module 320 which supports forms 316 a and 316 b. Ascan be seen, truss module 318 is longer than truss module 320.Accordingly, shortened truss modules (similar to module 120 of FIG. 7,but having only a single set of upper and lower struts) can be connectedto end frames 142 and 144 of truss module 320 in respective areas A1 andA2, so that the end frames of the shortened truss module 320 will alignwith the end frames 138 and 140 of truss module 318. Truss module 318essentially comprises two of the truss modules 118 (FIG. 7) joinedtogether at a truss pivot assembly 338. That is, truss module 318comprises space frame and strut assemblies 346 and 348 which are joinedtogether at truss pivot assembly 338. Truss sub-module 346 supports formsection 314 a, and truss sub-module 348 supports form section 314 b.Form sections 314 a and 314 b are hingedly joined at hinge 340, allowingthe form sections 314 a and 314 b to form a sharp angle, rather than acurved shape (as in FIG. 17). Likewise, truss module 320 comprisesstandard space frames 150 and 152, as described above, but space frame150 supports form section 316 a, while space frame 152 supports formsection 316 b. Form sections 316 a and 316 b are hingedly joined athinge 339, allowing the form sections 316 a and 316 b to form a sharpangle. The form sections 314 a,314 b,316 a and 316 b together form acorner area “C”. If a sharp outside corner is not desired, then arounding form can be placed between form sections 316 a and 316 b toround the corner. Each space frame 346, 348 of truss module 318 of thecorner forming apparatus 300 can be articulated at least 45 degreesabout a centerline “CL” which joins form hinges 340 and 339, andlikewise each space frame 150, 152 of truss module 320 can bearticulated at least 45 degrees about the centerline “CL”. In this waycorners of varying angles can be produced with the corner formingapparatus 300.

[0080] Since actuator frame 337 of truss module 320 of FIG. 19 does nothave a corresponding actuator frame in the truss module 318, the yokeassembly (such as 106 of FIG. 6) which is used to lift the apparatus 300upward along the climb rod (e.g., climb rod 99 of FIG. 6) is preferablylocated where two actuator frames correspond (i.e., where two actuatorframes are located adjacent one another between truss modules). Turningto FIG. 20, a plan view of a system 400 of a concrete structure formingapparatus in accordance with the present invention is depicted. Thesystem 400 is generally configured to produce a rectangular, verticalconcrete structure. The system 400 comprises four corner formingapparatus 300A, 300B, 300C and 300D. It is noted that corner formingapparatus 300A and 300B are joined along the long-dimensioned side ofthe rectangular form 400 by straight forming apparatus 100A, 100B, 100C,100D, and so on. At the short-dimensioned sides of the rectangular form400, truss modules 318A and 318D of corner forming apparatus 300A and300D are joined directly together. However, the truss modules 320A and320D of corner forming apparatus 300A and 300D are not joined directlytogether, but instead are provided with supplementary truss modules 120Nand 120M. Likewise, whereas truss modules 318A and 318D are joined torespective straight forming apparatus 100A and 100Z, supplementary trussmodules 120P and 120Q are provided to allow the outside truss modules320A and 320D of corner-forming apparatus 300A and 300D to connect tothe straight forming apparatus 100A and 100Z. As can also be seen inFIG. 20, each concrete forming apparatus that comprises part of theoverall system 400 is not necessarily provided with a yoke.Specifically, along the long-dimensioned sides of the rectangular shape400 only every other straight forming apparatus is provided with alifting yoke (e.g., apparatus 100A and 100C are provided with respectiveyokes 106A and 106C, while forming apparatus 100B and 100D are notprovided with yokes). However, along the short-dimensioned sides of therectangular form 400, yokes 106B and 106D are connected to respectiveinner truss modules 318A and 318D, as well as to respective outersupplemental truss modules 120N and 120M. As can be seen by the exampleprovided in FIG. 20, the number and location of yokes provided in anyconcrete forming system which includes concrete forming apparatus of thepresent invention will be governed by considerations such as thethickness of the concrete structure being formed and the final shape ofthe structure. The number and location of yokes will also be governedby: (1) resolving the hydrostatic forces of concrete exerted on theforms (114, 116) over the span of the truss modules (118, 120) to theyokes (106); (2) the gravity loads supported by each truss module 118,120 (e.g., the loads on the work decks 110, 112); and (3) the stabilityof the overall concrete-forming system as the weight of the system bearson the climb rods (99).

[0081] Turning to FIG. 21, a plan view of a modification to the concreteforming apparatus 100 of FIG. 6 is depicted in plan view. FIG. 21 showshow the apparatus 100 can be adapted with an “end-of-segment” adapter,which can be used when the apparatus 100 is operated in a segmentalcasting mode. The end-of segment adapter includes a segment end plate280 which is used to close the void area (90, FIG. 6) between forms 114and 116 as the structure of wall “W” is being formed. End plate 280(FIG. 21) has securing tabs 281 provided on the outside thereof. Thesegment end plate 280 is depicted in FIG. 21 as being pulled slightlyaway from the end face “E” of the wall “W” merely to illustrateoperation of the end-of-segment adapter. The end plate 280 is preferablythe same height as the forms 114 and 116. Hingedly attached to formbrace members 226 are form extenders 276, which each have an end platesecuring bracket 278 attached thereto. Securing brackets 278 andend-plate securing tabs 281 are each provided with holes (not shown)which will align when the end plate 280 is placed in position (to formend “E” of wall “W”) and form extenders 276 are rotated in directions“J”. A securing pin (not shown) can then be placed through the alignedholes in tabs 281 and securing brackets 278 to secure the end plate 280in position. After a formed segment of wall “W” has been cured, the endplate 280 is removed by removing the securing pins and rotating the formextenders 276 outward to the position shown in FIG. 21.

[0082] Turning to FIG. 22, a plan view of another modification to theconcrete forming apparatus 100 of FIG. 6 is depicted in plan view. FIG.22 shows how the apparatus 100 can be adapted with an “end-of-form”adapter, which can be used when the apparatus 100 is used to form theend segment of an open-form structure. The end-of-form adapters includeend-of-form extenders 282 which are hingedly attached to form bracemembers 226. Each end-of-form extender 282 includes an end-form 284.When the end-of-form extenders 282 are rotated in directions “J”, theend-forms 284 will cover the area “E” which will define the end of thestructure “W”. The end-of-form extenders 282 can be held in the “closed”position by the use of bolts or pins which can pass through mating tabs(not shown) on the end-forms 284.

[0083] Although I have described above a specific embodiment of aconcrete forming apparatus of the invention, it will be appreciated thatanother embodiment of the present invention provides for a concreteforming module (such as 102 of FIG. 6) which can be used to retractconcrete forms away from a concrete structure (or a partial concretestructure) which has been formed, or to move concrete forms into placeto form a concrete structure. The module 102 includes a concrete form(114, FIG. 6) and a first actuator frame 134. The module 102 furtherincludes a first form-translating actuator 200 which is supported by theactuator frame 134. A first elongated form-translating member (shaft184), which is engaged by the form translating actuator 200, has a firstend connected to the form 114. The form-translating actuator 200 isconfigured to move the form-translating member 184 relative to theactuator frame 134, to thereby translationally move the form 114relative to the actuator frame 134. Preferably, the module 102 furtherincludes a second actuator frame 174 which is spaced-apart from thefirst actuator frame 134, and connected to the first actuator frame, bya main frame 248. In this case the module 102 has a secondform-translating actuator (200) supported by the second actuator frame174, and a second elongated form-translating member (shaft 188) having afirst end connected to the form 114 proximate a lower edge of the form(the first translating member 184 being connected to the form 114proximate an upper edge thereof). The second form-translating member 188is engaged by the second form-translating actuator 200 (lower), and thesecond form translating actuator (lower 200) is configured to move thesecond form-translating member (188) relative to the second actuatorframe 174. Preferably, when two form translating actuators (200 upperand lower) are provided, the first and the second form translatingmembers (184, 188) are each connected to the form 114 by a hingedconnector (e.g., pin 192), allowing the form to “tilt”, such asindicated by 116 a in FIG. 8.

[0084] The concrete forming module 102 can further include a first spaceframe (146, FIG. 7) connected to the first side of the actuator frame134, and a second space frame 148 connected to the second side of theactuator frame. A first end-frame 138 can be connected to the firstspace frame 146 distal from the actuator frame 134, and a secondend-frame 140 can be connected to the second space frame 148 distal fromthe actuator frame 134. A work deck 110 (FIG. 6) can be supported by theactuator frame 134 and the first and second end frames (138, 140).

[0085] Yet another embodiment of the present invention provides for aconcrete forming module (such as module 102) which can be used to shapea semi-flexible concrete form into a curvilinear shape to thereby allowcasting of various geometries of structures, all using the same formmodule. The concrete forming module 102 includes a semi-flexibleconcrete form (such as form 114, which can be made of steel of asufficient thinness that it can be resiliently deformed into a desiredshape). The module 102 includes an actuator frame (such as frame 134,FIG. 7), and a form-shaping actuator supported by the actuator frame.The form-shaping actuator can be any of actuators 196, 198 or 200. Themodule 102 further comprises an elongated form-anchoring member (such asshaft 184) having a first end connected to the form 114 at an anchorpoint (e.g., at pin 192, FIG. 8). The form-anchoring member 184 isconnected to the actuator frame 134. This connection of theform-anchoring member 184 to the actuator frame 134 can be either afixed connection, or a moveable connection. The module 102 furtherincludes a form-shaping member (such as strut 155, 156, 206 or 208 ofFIG. 7) having a first end connected to the form 114 (as at form supportmembers 222, 224, 224 or 228 of FIG. 10), and a second end connected tothe form shaping actuator (e.g., 196, 198 or 200). The connection of theform-shaping member (e.g., strut 155, 156, 206 or 208) to the formshaping actuator (e.g., 196, 198 or 200) can either be direct, as in thecase of actuators 196, 198 (FIG. 8), or indirect, as in the case ofactuator 200 (where the connection is through the form-anchoring member(shaft 184)). The form-shaping actuator (196, 198 or 200) is configuredto produce relative movement between the second end of the form-shapingmember (e.g., the end of strut 155 which is closest to the actuatorframe 134, as seen in FIG. 7) and the anchor point (e.g., pin 192, FIG.8) to thereby urge the form 114 into a curvilinear shape.

[0086] In this latter embodiment the form-shaping actuator can beconfigured to move within the actuator frame to effect movement of thesecond end of the form-shaping member (e.g., strut 155) relative to theanchor point (e.g., pin 192). Specifically, actuator 196 or 198 can beused in the manner described above, wherein the “form-anchoring member”(shaft 184) is held stationary by actuator 200, so that actuation of thejack-screw actuator (196 or 198) causes the actuator 196, 198 to movewithin the actuator frame 134 on guides 194 (FIG. 8). Alternately, theform-shaping actuator can be configured to move the elongated anchormember relative to the actuator while the actuator remains stationary.This can be accomplished by using actuator 200 to move the “formanchoring member” (shaft 184) relative to the actuator frame 134.

[0087] A further embodiment of an apparatus 700 in accordance with thepresent invention is depicted in a side elevation view in FIG. 25. Theconcrete forming apparatus 700 of FIG. 25 comprises a first form 714 anda second form 716 placed in generally parallel, spaced-apartrelationship with one another to thereby form a concrete-receiving void90. The apparatus 700 further includes a yoke 706 comprising a first arm762 and a second arm 764. A first-form-translating member 730 isconnected to the first form 714 and is in moveable relationship to theyoke first arm 762. A first-form translating actuator 720 is configuredto move the first-form-translating member 730 relative to the yoke firstarm 762. The apparatus 700 can further include a second-form-translatingmember 732 connected to the second form 716, and in moveablerelationship to the yoke second arm 764 by virtue of a second-formtranslating actuator 722 configured to move the second-form-translatingmember 732 relative to the yoke second arm 764. A climbing device 708(similar to climbing device 108 of FIG. 6) can be provided to allow theyoke 706 to move upwards in direction “Y” as concrete wall “W” is formedon foundation “F”.

[0088] Another embodiment of an apparatus 800 for forming concretestructures in accordance with the present invention is depicted in aside elevation view in FIG. 26. The apparatus 800 of FIG. 26 includes afirst form 814 and a second form 816 placed in generally parallel,spaced-apart relationship with one another, as well as a yoke 806comprising a first arm 862 and a second arm 864. A first-form-shapingmember 830 having a first end connected to the first form 814 and asecond end in moveable relationship to the yoke first arm 862 is alsoprovided. The apparatus 800 can further include a first-form-shapingactuator 840 configured to move the second end of the first-form-shapingmember 830 relative to the yoke first arm 862. The apparatus 800 canalso include a second-form-shaping member 832 having a first endconnected to the second form 816 and a second end in moveablerelationship to the yoke second arm 864. When a second form-shapingmember 832 is provided, the apparatus 800 can further include asecond-form-shaping actuator 842 configured to move the second end ofthe second-form-shaping member 832 relative to the yoke second arm 864.The first-form shaping member 830, as well as the second form-shapingmember 832, can comprise adjustable-length struts configured to move thefirst end of the first-form-shaping member relative to the yoke firstarm.

[0089]FIG. 27 depicts a plan sectional view of the apparatus 800 of FIG.26, and shows how the form-shaping members 830 and 832 can be connectedto the respective forms 814 and 816, as well as the respectiveform-shaping actuators 840 and 842. FIG. 27 also shows that forms 814and 816 can be further provided with respective first-form andsecond-form secondary form shaping members 831 and 832, which can beconnected to respective first- and second-form shaping actuators 840 and842. As indicated in FIGS. 26 and 27, the yoke 806 of apparatus 800 caninclude a climbing device 808, allowing the apparatus 800 to ascend inthe upward “Y” direction along climb rod 99. By sharing forms 814 and816 using the form-shaping members 830 and 832, a shaped structure “W”(such as wall 22 of FIG. 3, or of FIG. 5) can be formed on thefoundation “F”.

[0090] I will now describe how the apparatus described above can beoperated.

[0091] I) Mobilization-Demobilization

[0092] Concrete forming apparatus of the present invention, such asapparatus 100 of FIG. 6, will typically be mobilized to and from aconstruction site in a state of advanced assembly. Several standardmodules 102, 104 can be connected in a chain (as in modules 100A, 110B,100C of FIG. 20) and transported in a straight format on a semi-trailerwith the opposed form faces (114, 116) set closely together and theactuator shafts (184, 186, 188, 190 of FIG. 8) retracted fully into theactuator frames (134, 136, 174, 176) to minimize the width of the modulepair (102, 104). Yokes 106 can be shipped in halves (e.g., arms 268 and270 of FIG. 14 shipped separately), with the jacking subassembly 108attached to one of the frame halves. Climb pipes 99 (FIG. 6) can bestacked as pipe. Attitude control modules 130 and 132 (FIG. 6) and othercomponents can be stacked on pallets.

[0093] II) Set-Up

[0094] Each module chain (comprised of several standard apparatusmodules 102, 104 in opposed pairs) can be lifted as a unit off of a semitrailer onto the foundation “F” (FIG. 6) or nearby on a flat, levelsurface. These module chains can then be manually configured,module-by-module, into the intended geometric format that will effectthe reinforced concrete wall or shell segment of the structure, or anentire structure such as shown in FIG. 20. Actuation of the modules 102,104 into the desired geometry is accomplished by setting struts (155,156, 206, 208, 158, 160, 210 and 212) to a predetermined length andsetting strut actuators (196, 198) to the predetermined location alongactuator shafts (184, 186, 188, 190). The adjustable links (234, 236,FIG. 11) of the space frames ((146, 148, 150, 152, FIG. 7) are allowedto telescope relative to one another during this actuation process toset the form geometry. Extender form adaptors such as 372 (FIG. 17B) andend-of-wall adaptors 282 (FIG. 22) can then be attached to the requiredform ends. Any required incremental length modules (e.g., 120M, 120N,120P and 120Q of FIG. 20) are inserted within and between the variousmodule chains to effect the exact curvilinear structural length desired.The adjustable links 234, 236 (FIG. 11) of the truss modules 118, 120can then be locked in place to freeze the structural shape. These modulechains are then lifted into place straddling the foundation dowel rebar(which typifies the base of most reinforced concrete structures), andtypically also a form height of completely-installed horizontalstructure reinforcing steel (“rebar”) (since there is little or noaccess to install this reinforcing steel after the forms 114, 116 are inplace). As these module chains and individual modules are landed on thefoundation, they can be rough-leveled. The free ends of the modulechains and individual modules are then pinned together with pins atcommon end frame anchor flanges 199 (FIG. 11), adjoining work deckpanels (such as 296, FIG. 17A) are set in place, and the adjoininghandrail is attached together. After the entire segment length (or wholestructure length) of modules 102, 104 are in place and pinned together,the modules are then fine-leveled (or set to a desired wall slope) byshimming under each flange of the end frames (e.g., 142, 144) and underthe actuator frames (134, 136). Yoke modules 106 are then lowered intoplace at their prescribed support location along the jump-slip formsystem (see FIG. 20, for example) and are attached and plumbed radiallyto a reference point, such as the end frame pairs (140, 144 of FIG. 7),a pair of actuator frames (134, 136) or at the frame support points(180, FIG. 8). The yokes 106 are then plumbed tangentially to the trussmodules 118, 120 by adjusting the upper support point (proximate upperflange 180) relative to lower support point (proximate lower flange180). Next, a climb pipe 99 (FIG. 6) is lowered down through the yokejacking assembly 108 to the foundation “F”. The initial climb pipe 99,as well as subsequent spliced climb pipes, can be sized to stick upabove the top of the yoke 106 by several form heights, so as to reducethe frequency of splicing subsequent climb pipes. The climb pipe 99 isplumbed tangentially (into or out of the plane of the sheet upon whichFIG. 8 is drawn), and plumbed radially (in directions “R1” and “R2” ofFIG. 8) (or set to a predefined radial slope for sloped walls),inherently by its reference to the bores on the upper and lower yokejacks (272, FIG. 14) through which the climb pipe 99 has been placed.Next, modular power and control units are mounted along the work decks(110, 112, FIG. 6) and connected to the truss module actuators (196,198, 200), the attitude control module actuators (260, 264, FIG. 13),yoke jacks 272, and GPS or other geometric monitoring and controlsystems. Any other support subsystems such as, but not limited to,welder leads, cutting torch gas lines, and climate control lines (formscan be provided with a climate control system to facilitate hot and coldweather concreting) can also be attached between modules 102 and 104 atthis time. The final activity before beginning construction of thereinforced concrete structure is to prepare the forms with a releaseagent, and globally actuate the forms 114, 116 into place relative tothe support truss structures 118 and 120. To insure a proper preloadbetween the forms (114, 116) and support truss modules (118, 120) on theinitial concrete lift (when in discrete casting mode), the bottom backedge of the forms (114, 116) at their middle and ends is preferablybraced to the concrete foundation “F” (FIG. 6) with concrete anchors.Subsequent preload (for the discrete casting mode) is accomplished bythrusting the bottom edge of the form face 114, 116 against the top edgeof the evolving concrete structure (such as wall “W”, FIG. 6) after ithas achieved adequate strength. The preload can compensate fordeflection or “bulging” of the forms 114, 116 due to the hydrostaticforces of the liquid concrete as it is deposited between the forms.

[0095] III) Operation

[0096] There are two primary modes of operation of the apparatus of thepresent invention: discrete casting and continuous casting, which areperformed by the apparatus to achieve either vertical segmental castingof discrete concrete segments, or casting of the entire structureall-at-once. I will now describe each of these modes separately.

[0097] a) Discrete Casting Mode

[0098] The set-up (described above) will have generally prepared theapparatus 100 for casting the first lift or jump of concrete, liftsbeing typically the form height in classical jump-forming, but in thecase of the “jump-slip machine” (apparatus 100, or 400 for example), theforms on subsequent lifts are overlapped somewhat with the previous pourto allow preloading of the forms against the cured concrete, and toeffect smoother, less noticeable, horizontal joints than is typicallythe case for prior-art jump forming wherein the forms are placeddirectly above one other (with no overlap). Prior to pouring concrete,any block-outs (e.g., door, windows, etc.) or embedments are placedbetween the forms 114 and 116, and fastened to the form faces withfasteners, and any spreaders (as discussed below) are attached to theforms 114, 116. The first “lift” is then poured into the void area 90(FIG. 6) between the forms (114, 116) by way of a concrete pump trucktrunk or a concrete bucket, and then vibrated until the form height isachieved. Although the support truss modules (118 and 120) and yokesystem 106 will generally be relatively rigid and will have beenpreloaded by the actuators (196, 198) relative to the form modules (114,16) to achieve tight geometric thickness control of the concretesection, even tighter dimensional tolerances at the top of forms 114,116 can be achieved by placing rigid steel spreaders at stiffenermembers (224, 228, FIG. 10) at the top of the forms around the perimeterof the forms before pouring. While sufficient time passes to cure thejust-poured concrete to a specified minimum strength before releasingthe forms 114, 116 for the next lift, reinforcing steel (“rebar”) can beplaced for the next lift of concrete. Access to place reinforcing andpour concrete is provided on both sides of the evolving structuralsection on the work decks 110, 112. The work decks 110, 112 can besupplied with concrete and reinforcing steel, and other materials, byway of individual equipment such as mobile cranes and concrete pumptrucks or, more preferably, it can be supplied with a specializedmodular tower crane which is located so that the swing of the boom ofthe crane has sufficient access to all parts of the segment or wholestructure (e.g., structure 400 of FIG. 20). Being modular in nature, thetower crane will be able to self-increment its height. At such time asthe reinforcing steel for the second lift is in place and the first lifthas attained adequate strength, the forms 114, 116 are released awayfrom the cured concrete, and can also be tilted as described inassociation with FIG. 8 (see tilted form 116 a). End-of-wall adapters(FIG. 22) and end-of-segment adaptors (FIG. 21) are also then releasedfrom the apparatus 100, and rotated away from the cast concrete, and anyend-of-segment end plates 281 (FIG. 21) are lifted to the next level.Before raising the jump-slip system 100, the forms (114, 116) arepreferably cleaned and oiled by personnel on the work-decks 110, 112 forthe next lift. (Cleaning before raising the machine to the next levelprevents loose concrete and oil from contaminating the cold joints.) Thetop edge of the cured concrete of the first lift is also cleaned of anyloose concrete so that the bottom edge of the forms 114, 116 willinterface cleanly with this edge and form a tight overlap. The jump-slipmachine (100 of FIG. 6, or 400 of FIG. 20) can then be raised to thenext level by activating the yoke jacks 272 (FIGS. 6 and 14). As thecontrol of the system is intended to be automated, an operator caninstruct a programmable logic controller (“PLC”) to execute the lift,and all forms will automatically be raised to the predeterminedelevation. Elevation can be monitored through an array of GPS sensorsthat locate the forms 114, 116 in three dimensions to thereby maintainthe intended structure geometry. Following the initial lift, there willnow be sufficient room between the form system (truss modules 118 and120) and the foundation “F” to attach the attitude control modules 130,132 (FIG. 6) using anchor flanges 178 (FIG. 8). This arrangement ofmounting the attitude control modules 130, 132 immediately below theyoke module 106 provides a rigid mounting, and will result in highdimensional control of the evolving structure by the modules 130, 132.However, due to openings or obstructions in the resulting structurewhere the radial attitude control modules 130, 132 cannot thrust off ofthe structure, the attitude control modules may need to be mounted tothe truss modules 118, 120 adjacent to the yoke arms 268, 270 (FIG. 14)on nearby actuator frames (frames 134, 136 of an adjacent apparatus100), or on the end frames (138, 140, 142, 144, FIG. 7)), or on thespaces frames (146, 148, 150, 152, FIG. 7). Once the attitude controlmodules 130, 132 are attached, they can then be connected to the powerand control system, and the PLC can be instructed to effect a fullradial alignment of the jump-slip system by way of simultaneously oriteratively actuating these attitude control modules (130, 132) usingactuators 260, 264 (FIG. 13). This radial alignment, in combination withthe yoke-climb pipe 99 tangential or sway alignment and verticalprogression (height of climb module 108), generally fully aligns thejump-slip machine in three dimensions a long the entire form perimeter.The form modules 114, 116 are then actuated back into thestructure-forming position, and the bottom edge of the forms arepre-loaded against the top edge of the first concrete lift over aspecified overlap distance that will not overload the just-pouredconcrete. Again, any block-outs or embedments can be inserted andfastened at this time, and spreaders can be attached to the form tops.Concrete is then poured again, as described above, and the discretecasting process is repeated until the full structure height is effected.Climb pipe 99 can be periodically spliced onto the existing climb pipewith threads and/or welds. Because the intended structure height may notbe a precise multiple of the “effective form height” (i.e., the actualheight of the forms 114, 116 minus the overlap), the final pour may bepoured to only some fraction of the effective form height.

[0099] b) Continuous Casting Mode

[0100] The set-up, described above, will generally have prepared thejump-slip machine (100 of FIG. 6, 400 of FIG. 20, for example) forcontinuous-mode casting. Typically the jump-slip standard module pairs(102, 104) will be delivered to the construction site as described inthe “set-up”, above, but they will have form liners, such as plywood,attached to the form faces 114, 116 to allow a continuous release of theconcrete as it is formed. Also, the extender form adaptors (such as 370.FIG. 17B) and any incremental form modules (such as 120M, 120N, 120P,120Q of FIG. 20) and end-of-wall adapters (e.g., 282, FIG. 22) orend-of-segment form adaptors (e.g., 276, FIG. 21) will also have formliners. During the set-up, the forms 114, 116 will have been actuatedinto a format that is relieved downward (i.e., the tops of forms 114 and116 will be slightly tilted towards one another, opposite of thedirection of tilt indicated by form 116 a in FIG. 9). This will allow asmooth transition of the form past the concrete, which will be invarious stages of setting-up and curing as the structure is beingformed. As with the discrete casting mode described above, prior topouring concrete any block-outs or embedments are placed within theforms and fastened to the form faces 114, 116 in the first form height.Unlike the discrete casting mode, in continuous casting operationsubsequent block-outs or embedments can be inserted in between the forms114, 116 amongst the continuous process of installing rebar and pouringconcrete. Continuous casting is initiated with the pouring of nearly thefull form height, and any final geometric changes to the structuralwidth are made at this time while the concrete is in a fluid state bymoving the individual strut actuators 196, 198 in or out using actuators200, and, to a limited extent, moving the strut actuators in or outrelative to the actuator shafts 184, 186, 188, 190 by actuating theactuators 196 and/or 198. Reinforcing (“rebar”) is installed essentiallycontinuously and simultaneously with the pouring of concrete. Thereinforcing progression should stay above the forms 114, 116 asufficient distance to allow inspection of the reinforcing before it iscast in concrete. In an automatic control mode, the PLC can be pre-setto activate simultaneously all yoke jacks 272 to effect a continuousupward progression of the jump-slip system 100 at a predetermined rate,which can be modified at any time to slow-down or speed-up the castingprocess to match the rate at which the personnel are installing thereinforcing and concrete, or depending on variances in concrete curingtimes. As the jump-slip system gets high enough off the foundation, theradial attitude control modules 130, 132 can be attached (as describedabove) and connected to the power and control system. The radialattitude control modules 130, 132 can then become an active part of thePLC-controlled alignment system and, together with the tangentialcontrol and elevation control, they can continuously maintain thejump-slip system 100 in the predetermined geometry within the allowedtolerances. When the height of the evolving structure permits, fixed ortrolley-type swing scaffolds can be attached to the actuator frames(174, 176, FIG. 8) and the end frames (138, 140, 142, 144, FIG. 7) toallow any required finishing of the slip-formed concrete surface. Thecontinuous casting process then proceeds as described above until thedesired structure height is achieved. As with discrete casting mode,climb pipe segments 99 are periodically spliced on to the previous climbpipe to maintain the yoke jacks 272 with a climb member to effectvertical or near vertical progression of the apparatus 100.

[0101] IV) Take-Down

[0102] After the concrete structure has been formed, the jump-slip formsystem (comprising a plurality of connected apparatus 100, or variationsthereof such as corner forming apparatus 300A of FIG. 20) can then belifted down from the completed reinforced concrete segment (or thecompleted whole structure) in module chains with a mobile crane orspecialized tower crane. Near the ground the radial alignment controlmodules (130, 132) and any swing scaffolds are preferably removed fromthe truss modules 118 and 120. Then the yokes 106 can be lifted to theground. The protruding climb pipes 99 can then be cut off flush with (orrecessed into) the formed structure and patched over. The remainder ofthe take-down is essentially the reverse of “set-up”, described above.

[0103] As can be seen by the foregoing description, the invention canfurther include a method of segmentally forming an essentially verticalconcrete structure (such as structure 600 of FIG. 24). The methodincludes providing a segment-section form which defines aconcrete-receiving section. The segment-section form comprises a firstface-form (e.g., form 114 of FIG. 6) and a second face-form (e.g., form116 of FIG. 6) placed in generally parallel, spaced-apart juxtapositionto one another. As indicated by FIG. 17, the face-forms 114 and 116 canbe in a curvilinear relationship to one another. The segment-sectionfurther includes a first segment-section end-form (e.g., 280, FIG. 21,or 284, FIG. 22) and second segment-section end-form. As indicated byFIGS. 21 and 22, the segment-section end forms are placed inspaced-apart relationship to one another, and are placed essentiallyperpendicular to, and between, the face-forms 114 and 116. The methodfurther includes depositing liquid concrete in the concrete-receivingsection, and allowing the liquid concrete to cure to a self-supportingsolid state, to thereby form a first-segment (601) first-section (602)defined by a first end (615). The method then includes moving thesegment-section form upward above the first-segment first-section (602),depositing liquid concrete in the concrete-receiving section, andallowing the liquid concrete in the concrete-receiving section to cureto a self-supporting solid state, to thereby form a first-segment (601)second-section (604) defined by a second end (617). The method canfurther include repositioning the segment-section form adjacent thefirst-segment first-section first end (615), depositing liquid concretein the concrete-receiving section, and allowing the liquid concrete inthe concrete-receiving section to cure to a self-supporting solid state,to thereby form a second-segment (603) first-section (620). It should benoted that the second-segment first-section 620 can be formed before thefirst segment (601) second section (604) is formed. The order in whichthe sections of the segments is formed will be dictated by theefficiencies and economies of moving the segment-section form from thefirst segment (601) to the second segment (602), versus moving thesegment-section form upwards from the first section (602 or 620) to thesecond section (respectively, 604 or 622).

[0104] The method can further include moving the segment-section formupward above the first-segment second-section (604), and then depositingliquid concrete in the concrete-receiving section. The liquid concretein the concrete-receiving section is then allowed to cure to aself-supporting solid state, to thereby form a first-segmentthird-section (606). As can be observed, the segment-section form can becontinually moved upward from the first-segment third-section 606 toform first-segment fourth section (608), first-segment fifth section(610), first-segment sixth section (612), and so on. Further, the methodcan further include moving the segment-section form upward above thesecond-segment first-section (620), and then depositing liquid concretein the concrete-receiving section. The liquid concrete in theconcrete-receiving section is then allowed to cure to a self-supportingsolid state, to thereby form a second-segment second-section (622). Ascan be observed, the segment-section form can be continually movedupward from the second-segment second-section 622 to form second-segmentthird-section (624), and so on. The order in which segments (601, 603)are formed is only relevant insofar as each additional section of eachsegment necessarily needs to be formed on top of the previously formedsection for that segment. That is, first-segment first-section 602 canbe first formed, then second-segment first section 620; thereaftereither first-segment second-segment 604 can be formed, or second-segmentsecond-section 622 can be formed.

[0105] When a climb-rod (such as 99 of FIG. 6) is provided, and thesegment-section form is guided by the climb rod (as described above withrespect to attitude control modules 130, 132, for example), the methodcan further include adjusting the position of the segment-section formrelative to the climb rod prior to depositing the liquid concrete for asubsequent section in a segment on top of a prior section in the segment(e.g., before depositing concrete for section 604 on top of section602).

[0106] While the above invention has been described in language more orless specific as to structural and methodical features, it is to beunderstood, however, that the invention is not limited to the specificfeatures shown and described, since the means herein disclosed comprisepreferred forms of putting the invention into effect. The invention is,therefore, claimed in any of its forms or modifications within theproper scope of the appended claims appropriately interpreted inaccordance with the doctrine of equivalents.

I claim:
 1. An apparatus for forming concrete structures, comprising: afirst and a second truss module; a first and a second concrete form; afirst and a second actuator device, each said actuator device mounted onthe respective first and second truss module and configured totranslationally move the respective first and second form with respectto the respective truss module; a yoke connecting the first truss moduleto the second truss module to place the concrete forms in generallyparallel, spaced-apart relationship; and a climbing device attached tothe yoke and configured to engage a climb rod and to move the apparatusalong the climb rod.
 2. The apparatus of claim 1, and further comprisinga first and a second attitude control module, each attitude controlmodule connected to one of the truss modules, and each attitude controlmodule comprising: an attitude control frame; an attitude positionerconfigured to contact a portion of an evolving concrete structure formedby the apparatus; and an attitude control actuator supported on theattitude control frame and configured to move the attitude positionerwith respect to the attitude control frame.
 3. The apparatus of claim 1,and further comprising a first and a second attitude control module,each attitude control module comprising: an attitude positionerconfigured to contact a portion of an evolving concrete structure formedby the apparatus; and an attitude control actuator supported on therespective first or second truss module and configured to move theattitude positioner with respect to the respective truss module.
 4. Theapparatus of claim 1, and wherein each truss module further comprises awork deck supported thereon.
 5. The apparatus of claim 4, and whereineach work deck comprises: a plurality of under-deck plates placed oneach truss module in spaced-apart relationship; a plurality of over-deckplates bridging the spaced-apart under-deck plates; and wherein theunder-deck plates and the over-deck plates are supported by the trussmodules in a manner which allows relative movement between theunder-deck plates and the over-deck plates.
 6. The apparatus of claim 1,and further comprising a yoke adjustment device positioned between theyoke and one of the truss modules to thereby allow the climbing deviceto be aligned to a predetermined reference point.
 7. The apparatus ofclaim 1, and wherein: the first and second forms are semi-flexible to alow the forms to be urged from a flat shape into a curvilinear shape;the first and second actuator devices are form-translating actuators,the apparatus further comprising: a first and a second form shapingdevice, each said form shaping device comprising: a form shapingactuator mounted on the respective truss module; a form shaping memberhaving a first end connected to the respective form, and a second endconnected to the form shaping actuator; and wherein the form shapingactuator is configured to move the second end of the form shaping memberrelative to the respective truss module, urging the form into acurvilinear shape.
 8. The apparatus of claim 7, and wherein the formshaping members comprise adjustable-length struts.
 9. The apparatus ofclaim 7, and wherein: the first and second form-translating actuatorseach comprise a threaded shaft connected to the respective form, andreceived within a first screw jack supported in the respective trussmodule in a fixed position; the form shaping actuators each comprise asecond screw jack which receives the threaded shaft, and which isslidably supported in the respective truss module.
 10. The apparatus ofclaim 7, and wherein each truss module comprises: a first and a secondspace frame; an actuator frame supporting the respective the first andsecond form-translating actuators, the actuator frame being positionedbetween the space frames; and wherein the space frames are attached tothe actuator frame in an articulable manner.
 11. The apparatus of claim10, and wherein each space frame comprises adjustable length links. 12.The apparatus of claim 1, and wherein the first and second actuatordevices are connected to the respective first and second forms proximatean upper edge of each form, the apparatus further comprising a third anda fourth actuator device connected to the respective first and secondforms proximate a lower edge of each form, and wherein the third andfourth actuator devices are mounted on the respective first and secondtruss modules and are configured to move the forms translationally withrespect to the truss modules.
 13. The apparatus of claim 12, and whereinthe first and the third actuator devices are connected to the first formby hinged connectors.
 14. An apparatus for forming concrete structures,comprising: two opposed concrete form modules which together areconfigured to provide a form for liquid concrete; a first and a secondtruss module, each truss module comprising: an articulable space frame;an actuator member having a first end connected to one of the concreteform modules; a form shape-altering actuator supported within theactuator frame, the form shape-altering actuator moveably engaging theactuator member; a plurality of extensible struts, each strut having afirst end attached to one of the form modules, and a second end attachedto the actuator; and a yoke connecting the first truss module to thesecond truss module.
 15. The apparatus of claim 14, and wherein thearticulable space frame comprises adjustable length links.
 16. Theapparatus of claim 14, and further comprising a work deck supported onat least one of the truss modules, the work deck comprising a pluralityof overlapping, articulable deck plates.
 17. A concrete forming module,comprising: a concrete form; an actuator frame; a form translatingactuator supported by the actuator frame; an elongated form translatingmember having a first end connected to the form, the form translatingmember being engaged by the form translating actuator; and wherein theform translating actuator is configured to move the form translatingmember relative to the actuator frame.
 18. The concrete forming moduleof claim 17, and further wherein: the actuator frame is a first actuatorframe, the form translating actuator is a first form translatingactuator, the elongated form translating member is a first elongatedform translating member and is connected to the form proximate an upperedge of the form, the concrete forming module further comprising; asecond actuator frame spaced apart from the first actuator frame, andconnected to the first actuator frame by a main frame; a second formtranslating actuator supported by the second actuator frame; a secondelongated form translating member having a first end connected to theform proximate a lower edge thereof, the second form translating memberbeing engaged by the second form translating actuator; and wherein thesecond form translating actuator is configured to move the second formtranslating member relative to the second actuator frame.
 19. Theconcrete forming module of claim 18, and wherein the first and thesecond form translating members are connected to the form by a hingedconnector.
 20. The concrete forming module of claim 17, and wherein theactuator frame is defined by a first side and a second side, theconcrete forming apparatus further comprising a first space frameconnected to the first side of the actuator frame, and a second spaceframe connected to the second side of the actuator frame.
 21. Theconcrete forming module of claim 20, and further comprising: a first endframe connected to the first space frame, and distal from the actuatorframe; and a second end frame connected to the second space frame, anddistal from the actuator frame.
 22. The concrete forming module of claim21, and further comprising a work deck supported by the actuator frameand the first and second end frames.
 23. A concrete forming module,comprising: a semi-flexible concrete form; an actuator frame; a formshaping actuator supported by the actuator frame; an elongated formanchoring member having a first end connected to the form at an anchorpoint, the form anchoring member being connected to the actuator frame;a form shaping member having a first end connected to the form, and asecond end connected to the form shaping actuator; and wherein the formshaping actuator is configured to produce relative movement between thesecond end of the form shaping member and the anchor point to i therebyurge the form into a curvilinear shape.
 24. The concrete forming moduleof claim 23, and wherein the form shaping actuator is configured to movewithin the actuator frame to effect movement of the second end of theform shaping member relative to the anchor point.
 25. The concreteforming module of claim 23, and wherein the form shaping actuator isconfigured to move the elongated anchor member relative to the actuatorwhile the actuator remains stationary, to effect movement of the secondend of the form shaping member relative to the anchor point.
 26. Theconcrete forming module of claim 24, and wherein the form shaping membercomprises an adjustable-length strut.
 27. A method of segmentallyforming an essentially vertical concrete structure, comprising:providing a segment-section form which defines a concrete-receivingsection, the segment-section form comprising: a first face-form and asecond face-form placed in generally parallel, spaced-apartjuxtaposition to one another; a first segment-section end-form and asecond segment-section end-form, the segment-section end forms beingplaced in spaced-apart relationship to one another, and placedessentially perpendicular to, and between, the face-forms; depositingliquid concrete in the concrete-receiving section; allowing the liquidconcrete in the concrete-receiving section to cure to a self-supportingsolid state, to thereby form a first-segment first-section defined by afirst end; moving the segment-section form upward above thefirst-segment first-section; depositing liquid concrete in theconcrete-receiving section; and allowing the liquid concrete in theconcrete-receiving section to cure to a self-supporting solid state, tothereby form a first-segment second-section defined by a second end. 28.The method of claim 27, and wherein the segment-section form is movedupward above the first-segment first-section in an essentially continualmotion while liquid concrete is deposited in the concrete-receivingsection.
 29. The method of claim 27, and further wherein the firstface-form, the second face-form, the first segment-section end-form andthe second segment-section end-form are retracted away from thefirst-segment first-section prior to moving the segment-section formupward above the first-segment first-section.
 30. The method of claim27, and further comprising rotating the combined first-segmentfirst-section and first-segment second section to an inclined position.31. The method of claim 27, and further comprising: repositioning thesegment-section form adjacent the first-segment first-section first end;depositing liquid concrete in the concrete-receiving section; andallowing the liquid concrete in the concrete-receiving section to cureto a self-supporting solid state, to thereby form a second-segmentfirst-section.
 32. The method of claim 27, and further comprising:moving the segment-section form upward above the first-segmentsecond-section; depositing liquid concrete in the concrete-receivingsection; and allowing the liquid concrete in the concrete-receivingsection to cure to a self-supporting solid state, to thereby form afirst-segment third-section.
 33. The method of claim 27, and wherein thesegment-section form is guided by a climb rod, the method furthercomprising adjusting the position of the segment-section form relativeto the climb rod prior to depositing the liquid concrete in thesegment-section form for form the first-segment second-section.
 34. Anapparatus for forming concrete structures, comprising: a first form anda second form placed in generally parallel, spaced-apart relationshipwith one another; a yoke comprising a first arm and a second arm; afirst-form-translating member connected to the first form and inmoveable relationship to the yoke first arm; and a first-formtranslating actuator configured to move the first-form-translatingmember relative to the yoke first arm.
 35. The apparatus of claim 34,and further comprising: a second-form-translating member connected tothe second form and in moveable relationship to the yoke second arm; anda second-form translating actuator configured to move thesecond-form-translating member relative to the yoke second arm.
 36. Theapparatus of claim 34, and further comprising a second-form translationactuator configured to move the second-form-translating member relativeto the yoke second arm.
 37. An apparatus for forming concretestructures, comprising: a first form and a second form placed ingenerally parallel, spaced-apart relationship with one another; a yokecomprising a first arm and a second arm; and a first-form-shaping memberhaving a first end connected to the first form and a second end inmoveable relationship to the yoke first arm.
 38. The apparatus of claim37, and further comprising a second-form-shaping member having a firstend connected to the second form and a second end in moveablerelationship to the yoke second arm.
 39. The apparatus of claim 37 andfurther comprising a first-form-shaping actuator configured to move thesecond end of the first-form-shaping member relative to the yoke firstarm.
 40. The apparatus of claim 37 and wherein the first-form shapingmember comprises an adjustable-length strut configured to move the firstend of the first-form-shaping member relative to the yoke first arm.